Bosal opens new Michigan plant
Bosal Group, the global manufacturer of exhaust systems and towbars, has announced the opening of a new state-of-the-art 17,000 m2 plant in Ypsilanti, Michigan.
The new € 17 million (c. $ 25 million) production facility combines at one site the previously separate Warren (MI) production site and Ann Arbor (MI) technical centre. It is designed to operate with world-class efficiency and quality standards in conjunction with lean manufacturing principles throughout for the development, test and production of OE exhausts. It is located close to major transport connections and the OEM technical and manufacturing headquarters of key customers including General Motors, Chrysler and Toyota.
Construction of the all-new plant started in June 2006 and was completed within 15 months. The eleven production cells from Bosal’s previous Warren site were seamlessly transferred to the new plant in ten weeks with zero impact on customer supply, enabling production at Ypsilanti to start in October 2007. The 17,000m2 facility has been built on a 40 acre site, allowing significant space for future expansion.
The new technical centre is significantly larger and features improved development facilities compared to the previous Ann Arbor site. Among its extensive new resources are a larger semi-anechoic chamber, with a four-wheel drive vehicle chassis dynamometer and a bigger prototype build shop.
John Miles, President of Bosal North America, said: “I’m very proud of this new facility and of how smoothly we completed the transfer of both the production and technical functions from the old sites. The new state-of-the-art manufacturing cells will allow Bosal to raise its already impressive productivity and service levels to its clients. Meanwhile our new technical centre, with a more comprehensive development and testing capability, will enable us to deliver exceptional new product solutions to existing and new customers.”
Karel Bos, chief executive of Bosal Group, said: “One of our most impressive plants around the globe, Ypsilanti is part of the latest phase of our commitment to delivering the very best value, quality and service to our customers from world-class facilities. In parallel to investments in the US, we have a number of similar developments under way around the globe to ensure Bosal remains an industry-leader in terms of R&D, production and supply.”
The vast majority of the 150 employees from the former Warren and Ann Arbor sites have transferred to Ypsilanti, aided by a subsidised employee bus transport scheme jointly funded by Bosal and Michigan state. The plant was built with due consideration of its natural environment, with epoxy flooring throughout and the successful retention of all local natural habitats and water features.