SULLY SUR LOIRE, France ArvinMeritor has opened a window regulator plant here to strengthen its position as Europes No. 2 door systems supplier.
The $14 million plant $9.4 million for construction and $4.6 million for tooling is part of a complex that has been making window regulators for more than 60 years.
ArvinMeritor also has its global door systems technical center at the site. ArvinMeritor, which controls about one-third of the European door systems market, is second only to Brose in the sector. The new plant boosts employment at the complex to 444 people: 229 engineers and 215 production workers. ArvinMeritor expects annual revenue for the window regulator plant to be about $159 million, with $116 million in purchases from Tier 2 suppliers.
From its Sully Sur Loire, plant, ArvinMeritor supplies Spain, the United Kingdom, Germany, Turkey and France. But more than 70 percent of the sites output is delivered to customers in France, mainly Renault and PSA/Peugeot-Citroen.
In addition, ArvinMeritor is negotiating with Toyota about supplying the Valenciennes, France, assembly plant from Sully. There are 73 suppliers to the site 48 are French companies and the rest are Spanish. The plant handles 650,000 individual parts daily, with 1,400 unique product lines.
The Sully site has adopted many lean manufacturing practices. It turns over its entire parts inventory and finished products every four to five days. It holds only about 70 tons of stock at any one time.
At the end of March, Sully held $2.1 million of stock, only one-third in finished product. Sully also uses flexible workstations. All the tooling is standard, meaning any product can be made at any workstation, and any workstation can be moved in only four hours.