ZF Chassis Modules (Solihull) Limited

Factory Tour at ZF Foxconn Chassis Modules Highlights Industry-Leading Efficiency

ZF Chassis Modules (Solihull) Limited — 14/03/2025

Members of Made in the Midlands congregated at the ZF Foxconn Chassis Modules (ZFFCN)plant in Solihull for a highly anticipated factory tour. Organised by Made in the Midlands and facilitated by Plant Director Adrian Chell, the visit provided an up-close look at ZFFCN’s state-of-the-art facility. Attendees gained valuable insights into how a global technology leader in driveline and chassis systems operates at peak efficiency.

Founded in 2024, ZF Foxconn Chassis Modules is a 50-50 joint venture between ZF Friedrichshafen AG and Foxconn (Hon Hai Technology Group), the global assembler of the Iphone. ZF, a world-renowned company with expertise in driveline and chassis technologies, boasts a long history of delivering innovative mobility solutions to global automotive giants. ZFFCN stems from a former ZF product line and therefore can draw on 30 years of experience in the field of axle system assembly. The Solihull site specifically focuses on producing advanced chassis modules to meet the ever-evolving demands of the automotive sector. With high-profile customers relying on just-in-sequence (JIS) deliveries, ZFFCN’s Solihull operations stand out for their meticulous execution and streamlined workflows—attributes strongly emphasised throughout the tour.

From the moment the group arrived, the facility’s disciplined structure was evident. Visitors were greeted by well-organised workstations, clearly delineated walkways, and digital boards displaying real-time production metrics. As the tour kicked off, Adrian Chell welcomed everyone with a brief introduction: “Here at ZF Foxconn Chassis Modules Solihull, our primary focus is on quality, safety, and efficiency. Every system we have in place is designed to maximise productivity, ensure the highest product standards, and deliver on-time results for our customers.”

Made in the Midlands, a manufacturing membership group dedicated to promoting industry collaboration across the region, had arranged the tour to showcase best practices in automotive manufacturing. Jason Pitt, CEO of the Made in Group, offered high praise for the site’s smooth operations, noting that ZFFCN embodies an exemplary level of manufacturing excellence: “ZFFCN’s Solihull facility runs like a finely tuned machine, and that is largely thanks to Adrian’s unwavering commitment to refined processes and his meticulous organisational skills. Every corner of this plant—every procedure—is carefully planned to achieve both speed and precision.”

Tour participants included professionals from various engineering and manufacturing backgrounds, all eager to glean new ideas for their own operations. The event’s structure allowed them to observe production lines at different stages of development, highlighting how ZFFCN utilises lean manufacturing principles and cutting-edge machinery to craft chassis modules. Guided by Adrian and his passionate ZFFCN plant team members Steve Shinton, Simon Hunt, Darren Whitehouse and Fiona Turner , the visitors learned about the crucial role JIS processes play in ensuring that each module is completed and shipped in the precise sequence required by the company’s customers—often prestigious automotive brands that operate with tight production schedules of their own.

During the walkthrough, Adrian explained how these JIS processes dovetail with another core element of the ZF Group’s success: continuous improvement. “We’re constantly refining what we do here,” he said. “Whether it’s tweaking a workstation layout to reduce employee strain or implementing new software to track component usage, we always look for small changes that can lead to larger efficiency gains. The automotive market is incredibly competitive, and our goal is to stay one step ahead by integrating best practices into every aspect of production.”

Attendees were particularly impressed by the level of employee engagement on the shop floor. Operators were trained to follow robust quality control measures, utilising digital tools that monitor key performance indicators in real time. Adrian highlighted that no matter how advanced the machinery might be, human skill and communication remain critical: “Our success depends on our people. We invest heavily in training programs, ensuring everyone understands not just their individual tasks but how they fit into the bigger picture. This awareness fosters accountability, makes problem-solving more dynamic, and ultimately helps us deliver exceptional quality.”

In one area of the plant, visitors observed robotic arms deftly assembling components with astounding speed and precision. Sensor-based systems provided immediate alerts if any deviations from specified tolerances occurred, prompting quick intervention and adjustment. Adrian pointed out how this synchronicity between automation and human oversight leads to minimal downtime and optimal consistency in parts production. He also emphasised that while automation can handle routine tasks, ZFFCN believes in maintaining a skilled workforce that can interpret data and oversee processes to avoid potential pitfalls before they escalate.

Throughout the tour, several members of Made in the Midlands asked questions about supply chain strategies, sustainability initiatives, and workforce development. Adrian provided candid and practical responses. On sustainability, for example, he mentioned that ZFFCN continuously seeks ways to reduce waste, conserve energy, and integrate eco-friendly practices, explaining: “Beyond just meeting industry standards, we want to proactively set benchmarks for environmental responsibility. This includes re-evaluating packaging materials, employing energy-efficient equipment, and recycling wherever possible. We’re part of a global network that shares knowledge and innovation, which allows us to keep raising the bar.”

For many attendees, the highlight of the visit was witnessing the plant’s live demonstration of just-in-sequence deliveries: completed modules were moved from the assembly line directly onto waiting trucks, organised in the exact order required by the customer’s own production schedule. This flawless orchestration underscored how ZFFCN’s attention to detail translates into tangible benefits for car manufacturers: timely deliveries, reduced inventory costs, and improved responsiveness to shifting market demands.

At the conclusion of the tour, participants gathered for a short debrief, during which Jason Pitt reiterated the purpose behind organising such events. “Part of our mission at Made in the Midlands is to facilitate learning and collaboration,” he said. “We want our members to see how industry leaders like ZF Foxconn Chassis Modules drive continuous improvement. Observing real-world applications of lean principles and advanced automation can spark new ideas for everyone here, no matter the size or scope of their own businesses.”

Looking ahead, both ZFFCN and Made in the Midlands expressed optimism about future partnerships. For ZFFCN, hosting such tours fosters openness and transparency, while showcasing their position as a best-practice leader in automotive manufacturing. For Made in the Midlands, it furthers the organisation’s goal of promoting regional growth and ensuring that innovative methods permeate the local supply chain. By the end of the day, attendees left armed with fresh insights into the transformative power of methodical processes, forward-thinking leadership, and a dedication to continuous improvement—all of which make ZFFCN’s Solihull facility a shining example of industry-leading precision.

Meet Britain's Makers: ZF Lemforder

ZF Chassis Modules (Solihull) Limited — 11/10/2023

In the heart of Solihull, where the spirit of British engineering has thrived for decades, we find ZF Lemforder, a tier-one automotive supplier known for its commitment to excellence. Recently, Made in Group CEO Jason Pitt had the privilege of visiting their state-of-the-art facility, shedding light on a company that epitomises innovation and precision in the automotive industry.

Driving Excellence in Automotive

ZF Lemforder is no stranger to the world of automotive manufacturing. They are renowned for their work with some of the globe's leading automotive brands and their contribution to the aftermarket. This visit, however, was more than a cursory tour; it was part of the Made in Group's ambitious plan to showcase the best of British engineering through a series of plant tours in 2024.

Hosting the visit was none other than Adrian Chell, the Plant Director of ZF Lemforder UK. Adrian is not only an expert in his field but also a passionate advocate for the sector. His more than six-year membership in Made in the Midlands and his upcoming delegation to Westminster illustrate his commitment to promoting the manufacturing and engineering industry.

Best Practices for Sustained Success

Adrian Chell shared valuable insights into the practices that have enabled ZF Lemforder to maintain a prominent position in an industry known for its ultra-lean operations. The moment one steps into the facility, the immaculate shop floor, operating with a just-in-sequence system and overhead lines, reflects a well-planned and organised plant.

Walking along the elevated platform, Adrian takes pride in showcasing the "fundamental skills room." This room, although condensed compared to the larger shop floor, contains many essential tools and components. What makes it unique is the presence of spinal diagrams and a 3D printed model of a person lifting heavy objects. It's a room that wouldn't be out of place in a chiropractor's office. The model serves as a visual demonstration of the consequences of incorrect lifting and offers solutions to improve ergonomics in various tasks.
Interestingly, the idea for this "fundamentals room" was inspired by a best practice visit to another business, which ZF Lemforder then adapted and enhanced to suit their own needs.

Challenges and Strategies

During the visit, Adrian discussed the challenges facing the sector, particularly regarding automotive OEMs (Original Equipment Manufacturers). Many larger automotive companies diversified their business during the pandemic to mitigate risks. However, this diversification posed challenges in maintaining lean production while accommodating the flexibility often required.

Adrian also shared ZF Lemforder's strategy towards achieving Net Zero emissions. He emphasised the importance of two standards, ISO 14001 and ISO 50001, which, when combined, cover a significant portion of the groundwork required for environmental preparedness.
Recruitment is another challenge that Adrian addressed. He highlighted the scarcity of skilled individuals with the right aptitude for the sector, even in a central location like Solihull. Adrian called for governmental leadership to bridge the skills gap and prepare the workforce for the manufacturing and engineering industry.

With a surge in customer orders, ZF Lemforder is creating new permanent roles, alongside their successful agency model. This flexibility, especially in the automotive sector operating a just-in-sequence line, proves invaluable when customers need to halt production for various reasons.
ZF Lemforder's commitment to excellence, innovation, and sustainability makes them a beacon of British engineering. Their willingness to share their knowledge and practices with industry peers through initiatives like the Made in Group's plant tours ensures that the legacy of British manufacturing continues to shine brightly.

The Made in Group organises monthly industry meetups online and in person. For details about joining on of our best practice sessions visit www.madeinthemidlands.com or www.madeinyorkshire.com

cubiX: Start of production for new ZF automotive software

ZF Chassis Modules (Solihull) Limited — 10/03/2023

Intelligent networking of all chassis systems for optimally controlled longitudinal, lateral and vertical dynamics
“Over-the-air” software update and upgrade capability
Lotus Eletre electric SUV is the world's first production vehicle with the new ZF software

For a pleasant driving experience, the longitudinal, lateral and vertical dynamics of a vehicle must be harmoniously coordinated. This is especially true for automated driving, when the driver turns away from active driving and the focus is on comfort. This is where ZF's cubiX software comes into play: It controls all chassis systems and ensures harmonious acceleration and braking, precise steering, and balanced damping.

In the beginning of 2023, the first production vehicles with the new ZF cubiX software have been rolling on the roads: The Lotus Eletre electric SUV from the Geely Group has been delivered to the first customers since February. From the middle of the year, the vehicle will be available in Europe. ZF's software controls all chassis functions such as brakes, front and rear axle steering, and active roll stabilizers as well as the electric drive of the new sports car. Further production start-ups of the innovative ZF software will follow from 2023.

"With the series premiere of our cubiX software, we impressively demonstrate our system competence for vehicle dynamics of software-defined vehicles," says André Engelke, Head of the Vehicle Motion Control System House at ZF. "We can harmoniously control the entire longitudinal, lateral and vertical dynamics of the vehicle according to Lotus' specifications. The system know-how from the entire ZF Group meets decades of experience in the fields of braking and steering systems, active dampers, and driveline technology."

Conductor for Vehicle Dynamics

The cubiX software optimizes driving behavior with a view to comfort, dynamics and efficiency and also forms the basis for progressive driver assistance systems. As ZF's first pure software product, cubiX offers another decisive advantage: The platform is compatible with various actuators such as dampers, brakes or rear-axle steering – regardless of the manufacturer or the specific design. This gives manufacturers the flexibility to implement different model series with one and the same control platform without additional integration effort.

Future updates or upgrades to the software can be carried out "over-the-air" – i.e. wirelessly without a visit to the workshop. In this way, the software remains up to date throughout the vehicle's life, meaning that additional functions can always be added after the vehicle has been delivered.

Architecture Change in the Software-defined Vehicle

cubiX is an example of a decisive trend on the way to the software-defined vehicle: away from the many individual controls of hardware components, towards overarching domain and zone architectures. This development takes into account the increasing complexity of automotive control software. Until now, dampers, brakes or rear-axle steering have each had their own control unit that has had to be integrated into the overall architecture of the vehicle.

The new electrical and electronic vehicle architectures bundle all the software for a specific functional area of the car – known as the domain – on a central control unit. "This overarching control saves vehicle manufacturers effort as well as compromises in fine-tuning and driving dynamics in terms of vehicle performance, comfort and efficiency. At the same time, it gives them the chance to combine complex assistance systems," explains André Engelke. "With cubiX, we have such software that can be perfectly integrated into the new architectures."

cubiX was developed at multiple ZF sites globally (Germany, Czech Republic, Romania, UK, India, and China), the application project driven out of Region Asia Pacific.