The Automotive Focus Group (AFG) was invited by German manufacturer ZF Lemforder to tour their assembly plant, in the ‘Detroit of the East’, at Pluak Daeng, Rayong. About 35 members and guests were able to attend this plant tour.
After an introductory briefing on the history and current status of ZF, the visitors were shown around the plant, which assembles suspension and other components for BMW, Mercedes, GM and Ford. Safety is a major focus of the plant, with all including the visitors required to wear long sleeved shirts and trousers, and closed shoes.
Separate assembly lines and storage areas are established for each customer, and for each suspension assembly. Some of the assemblies are built on a ten minute cycle, others on a twenty minute cycle, depending on the delivery rate required.
Each assembly is tested and performance recorded for future reference, then individual assemblies are barcoded for in field tracking. ISO 14001 standards are maintained, as well as meeting Thai Automotive Institute customs requirements.
Particularly impressive was a Mercedes subframe, gleaming in silver of mig welded high tensile aluminium. The Mercedes suspension components are then painted with a clear coat to provide additional protection against corrosion, and to preserve the exceptional appearance.
This plant largely relies on manual assembly, as the cycle times are not too fast, particularly on the luxury vehicles. Robots can be used in the future, if and when component demand dictates.
Following the tour, AFG members held a networking at Cafe De On, a Mexican Cafe near the ESIE estates headquarters, where much fine Mexican food was consumed, also a beer or two.
