ZF has produced 10 million Integrated Brake Control (IBC) units at its Fowlerville, Mich., plant since production began there in 2018. The facility now turns out roughly 6,500 Integrated Brake Control units per day for North American vehicle programs, according to the company, and has become ZF’s high-volume hub for the electro-hydraulic brake system.
Highlights
- 10 million IBC units produced at Fowlerville since the 2018 production launch
- About 6,500 units per day current output, per ZF
- 29% reduction in energy consumption achieved at the plant through automation, digital and energy-conservation projects
- More than 300 employees at the Fowlerville facility
What Is ZF Integrated Brake Control?
IBC combines brake boosting, the master cylinder, hydraulic control and electronic control in a single compact unit. ZF describes it as a non-vacuum, fully integrated electro-hydraulic system that supports automatic emergency braking, full energy recuperation and redundant fallback options up to fully automated driving in passenger car and light truck applications.
The company says the system improves braking performance, vehicle safety and system precision while supporting the industry’s move toward software-defined vehicles. ZF’s IBC systems are installed on several of North America’s highest-volume vehicle platforms, according to the company. The BRAKE Report covered the system’s production debut on the 2019 Chevrolet Silverado and, more recently, its role as the hydraulic core of ZF’s brake-by-wire portfolio.
“Producing 10 million IBC units is a significant achievement for our Fowlerville team. It is a reflection of their skill, commitment and focus on quality,” said Mario Sabel, ZF Senior Vice President of the Global Braking Systems Business Unit. “Since launching IBC production in 2018, the team has supported critical customer programs while helping establish Fowlerville as a leading ZF facility for advanced braking technology.”
Fowlerville Production Capabilities
The Fowlerville plant uses collaborative robotics, digital manufacturing systems and Industry 4.0 initiatives across its production lines. ZF cites these smart-factory technologies as the basis for the plant’s productivity and quality performance.
“Fowlerville demonstrates the manufacturing strength ZF brings to North America,” said Ramiro Gutierrez, President of ZF North America and Senior Vice President of the Global Steering Systems Business Unit. “This milestone shows how our regional footprint and technical expertise help customers bring critical safety technologies to market with quality, scale and resilience. As vehicles continue to evolve, capabilities like these will be essential to delivering future mobility solutions.”
Energy Reduction and Plant Outlook
Through automation upgrades, digital transformation projects and energy-conservation initiatives, the plant has cut energy consumption by 29%, ZF reports. The facility employs more than 300 people and continues to supply automakers across North America.
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