STUTTGART, Germany ― At the heart of Bosch’s Feuerbach factory in Stuttgart of Germany, a team of skilled workers in gray overalls carefully assemble the CP4 high-pressure diesel pump in a narrow work cell.

High-pressure fuel injection is one of the key advances that have transformed noisy, dirty diesel cars into smooth, tidy, powerful machines. Bosch, the world’s largest auto parts supplier, is undeniably a leading player in this field.

The assembly process begins as a transponder is attached to each pump and its production information is tracked electronically. The pumps then undergo diverse functionality tests before being shipped. 

Currently, the CP4 diesel systems are supplied to 95 car models of 25 brands, including Korea’s Hyundai Motor and its affiliate Kia Motors.

India and China are key markets for growth of the 127-year-old German company, but Korea is also crucial, said Klaus Bohler, executive vice president for the diesel systems division.

“Hyundai has been focusing on Europe. It has followed quickly with development of technology, making up 15 percent of the diesel market in the region,” he said. “The diesel market in Korea has now come a bit later. But they already have technology to use right away.”

Bosch early this month announced a new investment plan worth 170 billion won ($150 million) into the production of gasoline direct injection systems at its Daejeon plant in Korea.

The company, Bohler said, is also willing to spend more on its diesel business to support its key customer Hyundai to better respond to stricter emissions standards in Europe in the coming years.

“I’m so sure that sooner or later Hyundai will enter the U.S. market with its diesel models,” he added.

With carmakers ramping up efforts to meet more stringent emissions regulations such as the U.S. 10 and Euro 6, the Bosch veteran predicted that the company’s diesel systems business would see 3 to 4 percent annual growth by 2020.

Feuerbach, a district of Stuttgart, is global headquarters for Bosch’s diesel systems division. At the CP4 production building, which was set up more than 100 years ago, some 3,000 employees manufacture diesel products.

Despite its diverse customer portfolio, the assembly lines at the plant take only half an hour to cater to model-specific production. The failure rate is a stunning 0.3 percent, indicating nearly zero field problems.

“Product quality, flexibility and the following price competitiveness are key to this factory,” said Markus Zebisch, vice president and head of common rail pump production.

Even though the plant is a model of Bosch’s advanced manufacturing facilities with sophisticated machines and robots, people still play the key role in operating the whole production process.

“All of them are full-time workers. Their welfare, closely linked to product quality and work efficiency, is our top priority,” said the production head.

Thanks to Germany’s unique education system, which requires companies to offer an apprenticeship to young students, the workforce at the plant is a combination of all age groups with the average age of 41. 

By Lee Ji-yoon, Korea Herald correspondent
(jylee@heraldcorp.com)