Setting New Standards
Our Expertise at the Headquarters in Fichtenberg (Germany)
KW automotive, a globally represented company, has its headquarters in Fichtenberg, Baden-Württemberg. This is the mainstay for our OEM, aftermarket, and motorsport business areas. Highlights at our headquarters include a comprehensive testing center, extensive manufacturing capabilities, and the supply of our products on a build-to-order basis in batch size one.
Manufacturing
A wide range of resources in mechanical manufacturing and the in-house assembly of our components give us a significant competitive advantage. We place the highest emphasis on quality and flexibility. Our state-of-the-art manufacturing departments help us consistently achieve this goal.
Mechanical Manufacturing
In our mechanical manufacturing division, we process steel, stainless steel, aluminum, and plastic. We produce aluminum damper housings, top mounts, and many other components.
CNC Machines
2x Wagner WDS 480
1x Spinner TC400
3x DMG CTX Beta 500
1x DMG CTX Beta 800
2x DMG CTX Beta 800 4A with Robot
1x Spinner TC800 with bar loader and robot
1x DMG Milling Center Deckel MAHO
1x DMG MORI Milling Center DMU50
1x DMG CTS Beta 800 4A with Robot
Sheet Metal Processing
With a modern machinery fleet and highly qualified specialists, we transform raw materials into customized components. At our mechanical manufacturing facility in Fichtenberg, our expertise spans from laser cutting and bending to welding, allowing us to offer tailored solutions.
Laser Cutting Systems
Our laser cutting systems cut materials precisely, quickly, and efficiently. Among other systems, we use specialized fiber lasers that focus photons into a narrow beam. This results in precisely cut materials, ready for further processing.
Press Brake
Press brakes are essential tools in our mechanical production. These highly accurate machines bend metal sheets using a press plate.
Welding Department
The welding department is the heart of our mechanical production. Here, expert craftsmanship meets innovation. We use TIG and CMT welding methods. Modern machinery supports our skilled professionals. The Fichtenberg location holds a welding certificate under ISO 9606-1 141 T BW FM5 S s2 D50 PH ss gb.
Assembly
Flexible work processes and an incredibly high level of production depth, approaching 100%, allow us to produce custom products. Depending on the product specification, our damper, and suspension assembly can produce up to 500 dampers per day on a build-to-order basis.
Build-to-Order Philosophy
With the build-to-order (BTO) principle, products are manufactured on a per-order basis in batch size one. This ensures maximum flexibility despite a wide variety of product options. We offer a suspension solution and accessories for nearly every vehicle model.
Production under the BTO principle begins only after the order is received. Once an order is placed, we custom-build the coilover suspensions for the specific vehicle model. We also accept special custom orders. Every product and its components undergo multiple inspections by various employees to ensure integrity and functionality. The BTO principle allows us to maintain the highest levels of flexibility, quality, and individuality.
Lean Production as a Key Component of Our Efficiency Improvement
We have successfully applied the Lean Production philosophy for many years. This method optimizes our production processes by eliminating waste. We follow the “pull principle,” producing only according to customer demand. This philosophy is embedded throughout the company. It allows us to continuously improve all processes at KW automotive, making us more efficient and sustainable.
Logistics
After the manual goods receiving, components are assigned to automated systems for storage. We have 19,280 storage locations available.
The automated small-parts warehouse with 630 double cycles per hour supplies the assembly line. The automated pallet warehouse has 4,120 pallet locations for grid box pallets. This supplies our coating process with raw springs. Goods are transferred to containers in bulk, which are then stored in the AKL. The Storeware software manages these processes, sorting pallets and defining the sequence of orders. It also predicts material wear, allowing us to replace parts proactively, maximizing system uptime, and avoiding downtime.
Logistics
In collaboration with the company Gebhardt, we digitized our production and logistics processes in 2020. All process chains – from incoming goods to damper and chassis final assembly to shipping – have been automated.
After the manual goods receiving, components are assigned to automated systems for storage. We have 19,280 storage locations available.
The automated small-parts warehouse with 630 double cycles per hour supplies the assembly line. The automated pallet warehouse has 4,120 pallet locations for grid box pallets. This supplies our coating process with raw springs. Goods are transferred to containers in bulk, which are then stored in the AKL. The Storeware software manages these processes, sorting pallets and defining the sequence of orders. It also predicts material wear, allowing us to replace parts proactively, maximizing system uptime, and avoiding downtime.
Development Center
Research
Development Workshop
Our in-house workshop allows us to flexibly and directly install all our products and prototypes. In total, we have eight workshop spaces with lifting platforms and one axle measurement platform.
Simulation and Design
This early stage of the development process accompanies us from the idea to the finished product. At our headquarters in Fichtenberg, we use a combination of in-house developed and proven simulation tools to test our products in a resource-saving and flexible manner.
Real-world Testing
Before our products are installed and brought to market, we rigorously test them under stress. We have endurance test benches with different speeds and nominal forces. A unique highlight is our vehicle dynamics test bench with up to seven actuators, allowing us to simulate different track conditions and their effects on the vehicle without driving a single meter.
The Fichtenberg Development Department
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