Bosch eXchange alternators from Bernolákovo

As the only Bosch plant in the world for alternator reconditioning, the Bernolákovo site in Slovakia represents a cutting-edge asset for the firm when it comes to resource-saving circular economy in the automotive aftermarket. Every remanufactured alternator that comes from the Bernolákovo site is part of the Bosch eXchange program. This all-makes program includes starters and alternators from various manufacturers and therefore covers a large number of passenger cars, vans and trucks.

At the end of April, the Auto Trade Journal made the journey to Slovakia as part of a Bosch European press trip, to learn more about this compact, yet state-of-the-art facility, writes Eoin Cuttle.

Series remanufacturing in Bernolákovo
Bosch has been remanufacturing starters and alternators for more than 50 years, and has been operational in Bernolákovo for half of those. The 20,000sqm site, located around 18km from the capital Bratislava, today employs around 200 dedicated and skilled men and women who together are responsible for an annual output of almost 250,000 units. Half of the employees have been working there for over a decade, while eight have been working at the site since it opened in 2000. An observation from the tour was that the site is heavily reliant on these well-trained employees, as little to no automation is present.

In addition, more than 20 experienced developers are focused on the development of remanufactured products as well as product releases and testing to ensure the high quality of the finished products. Beside that, findings from the analysis of field returns in the local competence centre for quality assurance are incorporated into the further remanufacturing process as improvement measures.

Certified to OE standards
Like all Bosch remanufacturing plants for starters and alternators, Bernolákovo is also certified according to the OE standard IATF 16949. This means that the entire industrial remanufacturing and approval process is certified and carried out according to the strict standards of the original equipment. Besides the independent workshop market, also various vehicle manufacturers are supplied from Bernolákovo for their aftermarket business. For this purpose, the plant is also audited and certified accordingly by the manufacturers.

The process
The production lines at the Bosch plant in Bernolákovo meet the current technical standards and are equipped with modern test benches. Ergonomics are also taken into account in the work process to ensure the health of the employees. For example, for two-handed processing, the alternators are firmly clamped during dismantling. During series remanufacturing, all parts and components are consistently checked for strict adherence to the permissible tolerances and, if necessary, remanufactured or replaced with new parts approved by Bosch.

For the remanufacturing of certain individual components, special cleaning methods are used. Dry or wet cleaning is tailored precisely to the individual part. This also includes special cleaning programs. For example, when sandblasting the stators, special plastic caps cover the stator winding heads to protect the copper wire winding from damage. The rotors, on the other hand, are irradiated at a precisely de ned angle in order to reduce the stress on the insulation of the copper wire.

Uncompromising quality
To ensure that workshops can install high-quality alternators in their customers‘ vehicles, consistent quality management is carried out. This includes strict product release processes and quality assurance measures. Even before series remanufacturing starts, the products pass an approval process based on the original equipment standards. Using a series of test methods, they are checked under extreme conditions, for service life, vibration resistance, robustness to environmental influences and tightness.

This means that only products that meet Bosch‘s high quality standards are included in the Bosch eXchange program. All components undergo visual and dimensional inspections. Electrical components are measured and tightness is confirmed with pressure tests. In the so- called end-of-line test, the products must pass the final electrical test. Only then is approval granted and they are allowed to leave the factory.

Sustainability and circular economy
Due to increasingly scarce resources, the intelligent and sustainable use of raw materials is becoming increasingly important. This includes continuing to use products for as long as possible and extending their life cycle. One focus is on the circular economy, where remanufacturing is an important part of the process. Reusing parts during remanufacturing keeps materials in circulation for longer and conserves resources. For example, when remanufacturing alternators, depending on the application, 70 – 80 per cent of the original components are reused.

Tomáš Danter, managing director of the Bernolákovo plant, concluded the tour by saying: “When it comes to value-based repairs in workshops, Bosch eXchange alternators play an important role. This is particularly due to their high quality with an excellent price-performance ratio. Today they are an example of the resource-saving circular economy in the aftermarket.”