German Quality Service support installation and SOP production lines, laboratory and the Quality department, APQP
Purem by Eberspächer’s Flagship Automotive Factory in Kuala Lumpur
The Vision
In a bold commitment to drive clean and quiet mobility, Purem by Eberspächer set out to establish its newest manufacturing stronghold in Kuala Lumpur. The project’s ambition was to build a fully integrated facility dedicated to producing advanced exhaust aftertreatment systems. These systems, designed for both traditional combustion and next-generation hybrid engines, would meet stringent international emission standards and support the rapidly evolving Southeast Asian automotive market.
To ensure every decision reflected modern efficiency, the planning phase was transformed into a digital experience. Using interactive digital twin models and virtual design platforms, key stakeholders—ranging from in-house engineers to regional partners—could explore every detail of the prospective facility. Interactive dashboards rendered real-time analytics on layout simulations, production flows, and environmental impact, thereby aligning the project with both operational excellence and sustainability.
Planning & Digital Interactivity
The initial phase was defined by visionary strategy and deep digital interactivity. The project team with Hans Lozay:
- Employed Digital Twin Technology: A virtual replica of the planned 5,000-square-meter facility allowed for simulated walkthroughs of production lines, quality control zones, and R&D areas. This helped pinpoint potential bottlenecks before physical construction began.
- Utilized Interactive Timelines & Dashboards: Every critical milestone—from site acquisition to equipment installation—was tracked on an interactive, web-based dashboard. This not only improved transparency with investors but also enabled real-time troubleshooting and process optimization.
- Collaborated Across Borders: Digital collaboration tools bridged geographical gaps, allowing local Malaysian experts, international advisors, and our project leadership to engage in real-time problem solving and strategic planning.
This digital-first approach laid a solid groundwork for execution, establishing trust through measurable goals and a clear visual roadmap.
Execution & Innovation
Once the project blueprint was finely tuned, construction commenced on a new greenfield site just on the fringe of Kuala Lumpur’s bustling innovation corridor. Here’s how execution unfolded:
- Rapid Construction: Within a 14-month timeframe, the once-vacant lot transformed into a thriving factory complex. Modular construction methods and just-in-time delivery of equipment ensured adherence to tight deadlines.
- Advanced Manufacturing Integration: The production lines featured state-of-the-art robotics, automated quality checks, and smart sensor networks. These systems fed data into the pre-established digital dashboards, allowing continuous monitoring of production metrics and energy efficiency.
- Sustainability by Design: Emphasis was placed on environmental stewardship. Renewable energy systems, such as solar installations and energy recovery units, complemented the plant’s design—achieving significant reductions in waste and emissions.
Every phase was digitally documented and available for interactive review, giving stakeholders access to live updates, production stats, and quality control insights.
Impact & Legacy
At its grand opening, the Kuala Lumpur facility was celebrated not only as a technical triumph but also as an economic boost for the local community. Within months of launch:
- Production Milestone: The factory reached an inaugural production target of 200,000 components annually, positioned to serve key automotive markets across Asia and beyond.
- Job Creation & Skills Development: Over 150 local experts were employed, supported by partnerships with regional technical institutes. Tailor-made training programs by German Quality Service equipped the local workforce with advanced manufacturing skills, setting a benchmark for future industry-academia collaborations.
- Global Industry Influence: Purem by Eberspächer’s achievement signaled a new era for greenfield projects in emerging markets. The facility quickly became a reference model for how interactive digital tools can elevate the planning, execution, and management of complex industrial projects.
In addition to production success, interactive elements continue to play a vital role. An embedded digital twin now offers remote investors a 24/7 view of live production data, while dynamic dashboards display real-time environmental metrics and energy usage—to further exemplify the plant’s commitment to transparency and sustainability.
