Walking down the almost pristine aisleway at Brose North America’s Tuscaloosa, Alabama manufacturing facility, it is clear that this is no ordinary plant. Visitors are greeted with eye smiles above face masks and hand waves to signify a heartfelt welcome as workstations are passed and seat adjusters and door modules are methodically assembled for delivery to customers. It is an amazing sight to see the seemingly perfectly choreographed dance of the assembly associates load and unload parts from bins to robotic machine back to bins again, perfectly timed to the beat of the state-of-the-art equipment.
For more than 100 years, Brose has been supplying products to the automotive industry and in 2004, this German based, family-owned business made the wise decision to join the growing list of manufacturing companies with a presence in Alabama. Today, with more than $7 billion in sales, Brose serves premium customers throughout the world while still maintaining family ownership and family values. In fact, every other new car worldwide is equipped with at least one Brose product and the employees in Alabama could not be prouder.
Recently, Brose’s Alabama manufacturing facility earned the prestigious honor of being selected as one of IndustryWeek’s 2021 Best Plants Award winners, one of only three plants recognized in North America. IndustryWeek recognized Brose Tuscaloosa for exceptional manufacturing performance in 2021 amid a global pandemic, while maintaining quality, optimizing production and, most importantly, maintaining team morale during a year filled with adversity.
“The key to our success in Alabama has been our talented team of associates and the emphasis we place on providing them a safe and positive work environment,” said Nina Butler, Director of Human Resources. “Employees are given opportunities to grow professionally, and they know that not only do we value them, but we invest in them though continuing education and training. In addition, we take seriously our responsibility to the communities in which they live and support local school initiatives such as Modern Manufacturing, and non-profits such as Habitat for Humanity.”
Brose Tuscaloosa began production of door systems, cooling fan modules and seat adjusters in 2004. To meet growing customer demand, the facility has invested $14 million in infrastructure, including a drive-in acoustics chamber, state-of-the-art measurement laboratory and a 9,150 square-foot expansion of office space. The facility also added 400 jobs in recent years, fulfilled partially through its award-winning hands-on apprenticeship program and its philosophy of putting associates FIRST: Family, Innovation, Respect, Success, Team.
“I love Brose and Brose loves me. Brose is my family,” said Tywana Woodie, long time Brose associate. That attitude is mirrored by many of Woodie’s coworkers.
According to Jerry Braden the employees of Brose are why he joined the team nine years ago as the safety and security coordinator and why he stays. “I love that our employees know they can stop and talk to me and everyone on the management team at any time to make recommendations or voice a concern,” he continued.
Brose never settles for good enough and strives to be and partner with the best. Since the opening of the Tuscaloosa plant, Brose’s partner in maintaining a safe work environment for employees has been the Alabama Self-Insured Worker’s Compensation Fund (THE FUND). For more than 17 years, Brose and THE FUND have worked together to analyze data and develop innovative programs to make the workplace safer. This relationship is one reason why Brose Tuscaloosa has become a safety model for other facilities around the world. Through this relationship, injury frequency has been reduced by almost 70 percent.
“Any award our facility achieves is due to the individuals at Brose Tuscaloosa whose hard work and dedication to safety, efficiency and innovation drive quality in the most challenging of times,” said Jim Barbaretta, general manager. “Brose Tuscaloosa is a lean organization that serves as a performance benchmark to our peers and receiving recognition on a national scale inspires our continual focus on excellence.”
Walking through the facility, it is hard to miss the “Work safe. Work PROUD” posters hanging throughout the manufacturing area. As the IndustryWeek award exemplifies, these aren’t just words: this is life at Brose Tuscaloosa.