Mahle Behr has started production of engine cooling module for latest BMW X3 generation

Automotive air conditioning and engine cooling systems company Mahle Behr South Africa (MBZA) has recently launched its new production line at its plant in Durban. The new line will manufacture the engine cooling modules (ECM) for the latest (G45) generation of BMW’s X3 car.

The G45 ECM production line is currently ramping up to full capacity, in parallel with the start of local production of the X3 (G45). The ECMs assembled in Durban will be shipped to BMW’s Rosslyn assembly plant, in Pretoria, for installation in the new cars.

“Localisation remains a key priority for [MBZA] and we have achieved this through the utilisation of locally sourced aluminium as well as plastic granules,” reports MBZA MD Juergen Wolf. “The new G45 line will operate in a flow-line assembly process which will see the introduction of Artificial Intelligence (AI) for the first time in the manufacturing process at [MBZA].”

The company has estimated that 80% of the manufacturing of the ECMs will be done in-house. The aluminium is used to make the tubes, headers and side supports of the radiators. The plastic tanks that also form part of the ECM are being made using a recently commissioned 1 050 t injection moulding machine. As for the ECM subcontractors, MBZA is providing them with technology transfer and skills development.

The company’s own staff have been trained in the use of AI, allowing them to upskill. AI is allowing the plant to maintain a constant productivity rate of more than 70%. “Improved inspection processes and lower error rates are some of the advantages, in addition, our customers will benefit from ever-improving quality,” he highlights.

MBZA is also active in supporting communities close to the plant, and from which its workers come. Part of this is its Science2Go mobile science laboratory. This provides maths and science tuition to more than 80 000 local learners every year.