Behr Completes Two-Year Revamp Of Charleston Production Facilities

CHARLESTON, S.C., June 5, 2013 /PRNewswire/ -- Behr America's Behr Heat Transfer Systems has completely redesigned the layout of its production facilities in Charleston to improve efficiency and better support current and future customer demands.

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Productivity has increased by nearly 20 percent and scrap rates have dropped by 50 percent as a result of the restructuring program and employee efficiencies, according to Tom Daffron, the Charleston plant manager.

"We've seen significant improvements in efficiency which undoubtedly will translate into higher levels of customer satisfaction," Daffron said. "Without the dedicated efforts of our entire team of Charleston employees, as well as excellent support from many others in Behr's global organization, we could not have completed this project so successfully."

The Behr program included an entire redesign of the plant's layout, involved the relocation of virtually every piece of production equipment and took nearly two years to complete.

Since Behr began production in Charleston in 1993, its 350,000-square-foot facility, which supplies a variety of heat transfer units for primarily heavy truck customers, has undergone a number of changes, including the installation and removal of various process equipment. With plans to install a new, high-capacity furnace in 2011, Behr saw an opportunity to redesign the entire facility to meet the need for future improvements in material flow and overall efficiency.

To meet immediate and longer term needs, the company embarked on an aggressive development program.  The three-phased project involved moving production cells, furnaces, core builders and stock areas without disrupting production, affecting quality or impacting customer's service. 

To celebrate the team's success, the plant recently hosted an Open House for its nearly 400 employees, as well as their families and friends, featuring plant tours, vehicle displays, machine demonstrations and children's activities.

Behr's North American headquarters is in Troy, Michigan. Behr America has more than 2,700 employees at facilities in Troy, Mich.; Dayton, Ohio; Charleston, S.C.; Fort Worth, Texas, and Ramos Arizpe, Mexico.

Behr Heat Transfer Systems, Inc. employs approximately 390 people, producing radiators, CAC (Charge Air Coolers), EGRs (Exhaust Gas Recycling) and Engine Cooling Modules, primarily for heavy truck customers.  The facility is located at 4500 Leeds Avenue, Charleston, SC 29405.

Behr GmbH & Co. KG, Stuttgart, Germany, is a systems partner for the international automobile industry. A specialist for automotive air conditioning and engine cooling systems, the Behr Group is one of the world's leading manufacturers and suppliers of original equipment for light vehicles and trucks. Group sales in the 2012 business year came to around EUR 3.7 billion. Currently, Behr employs some 17,300 staff at 38 production locations as well as at regional R&D centers worldwide. The MAHLE Group holds a minority share of 36.85 percent in the Behr Group.

Additional information is available at www.behrgroup.com.

SOURCE BEHR America