THE POWER OF

Magazine2021

Keeping a cool head—p. 14
MAHLE takes a holistic approach to thermal
management—and can thus give a boost to
the new generation of electric vehicles.

Lighthouse project in Parma—p. 20
The Italian location proves that
innovation and climate protection
can go hand in hand.

At a glance
MAHLE is a leading international development
partner and supplier to the automotive industry
as well as a pioneer and technology driver forthe mobility of the future.

5
business units
Engine Systems and Components, Filtration and Engine Peripherals,
Thermal Management, Electronics and Mechatronics, Aftermarket

Around160

production locations

12
major research &development centers

71,298

employees
as at December 31, 2021

EUR 10.9 bn
sales in 2021

Editorial
Dear readers,even in these eventful and challenging times, MAHLE remains a company with solid
technological substance, far-reaching expertise, and an imperative to innovate.
These strengths shine out from the following magazine pages.
“Every gram matters” talks about the goal of providing the generation being born
today a climate-neutral future. We are contributing by developing technologies that
reduce CO2 emissions as much as possible, ranging from hydrogen engines to
e-compressors. MAHLE has set a course for climate-neutral mobility. We have a
wealth of ideas and can build on 100 years of experience. At the same time, wewill continue refining our MAHLE 2030 strategy. “Lighthouse project in Parma”
captures a vivid snapshot of what that future may look like.
In 2021, our development teams also made key advancements in the most dynamic,
trend-setting field of the automotive industry: e-mobility. The first highlight thatcomes to mind is the magnet-free electric motor. With this “Declaration of independence,” we’re proving that climate-friendly drives don’t require critical raw materials.
This is an important finding given the continued volatility of the markets. Having
in-depth understanding of integrated systems is also vital—or rather, forward-looking:we don’t just think in terms of individual components. As One MAHLE, we focus on
the big picture. To find out what this could mean for the breakthrough of e-mobility,
turn to “Keeping a cool head.” In that article, our experts explain why an over­arching approach to cooling and heating is essential in the electric era.
Any business wanting to take on all these challenges so as to play an active part in
the transformation of mobility needs a flexible team. Our MAHLE teams worldwide
are putting their heart and soul into this company, especially in these economicallyand geopolitically difficult times. “You never stop learning” showcases employees
who are actively engaged in the transformation—not just professionally, but
personally too. And they’re clearly enjoying it.
Based on these insights, I can say for 2022 that we want to continue to be a pace­setter and pioneer in our industry. We want our employees to contribute theirtalents and expertise to MAHLE with pleasure and enthusiasm. After all, the powerof Pioniergeist is in our genes—and evident throughout the next 40 pages.
I hope you enjoy reading about MAHLE’s pioneering work.

Michael Frick
Deputy Chairman of the Management Board and CFO

PIONIERGEISTMagazine 2021

1

Contents

4

14

4

Every gram matters
The EU aims to be climate-neutral by 2050. Technologies
from the mobility industry are therefore in demand.
Besides its e-mobility portfolio, MAHLE also offers othersolutions with direct benefits.

12#StrongerTogether
In the second year of the pandemic, the people at MAHLE
have again demonstrated their extraordinary commitment
to “ONE MAHLE.”

14

Keeping a cool head
Appropriate thermal management will play a decisive role inthe breakthrough of e-mobility. MAHLE addresses the topic
by means of complete systems.

2

Contents

20

20Lighthouse project in Parma
Innovative thinking and climate protection can go
hand in hand. This is illustrated by a visit to the newService Solutions center in Parma (northern Italy).

26“Sustainability is
all-encompassing”
Since the beginning of 2021, Kathrin Apel has been
responsible for sustainability management at MAHLE.
In the interview, she elaborates on the benchmarks
the company wants to set.

28

Declaration of independence
One step toward more sustainable mobility: MAHLE isdeveloping an electric motor with maximum efficiency
that does not require rare earth elements.

28

32

You never stop learning
The automotive industry is not only undergoing a rapidtransformation in terms of technology. With global training
programs, MAHLE offers its employees the opportunity toplay an active role in the transformation.

32

38

Highlights 2021

42

Imprint & contact

43

MAHLE worldwide
PIONIERGEISTMagazine 2021

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EveryThe EU aims to be climate-neutral in all areas oflife and the economy by 2050. A child born today
will be able to judge whether this goal has beenreached by their 28th birthday at the latest. If every
gram of CO2 saved between now and then matters,
every opportunity and every climate-friendly technology should be embraced. In addition to MAHLE’s
portfolio for e-mobility, three innovative solutions
have the potential to make a major contribution toclimate-neutral transportation.

4

Every gram mattersgrammatters
PIONIERGEISTMagazine 2021

5

Is 28 years a short time or a long time? In view of the inter­
generational challenges, the European Union’s goal toachieve climate neutrality by 2050 is certainly highly ambitious. According to German news magazine DER SPIEGEL’s
climate ticker, we have 7.42 years left at the time of writing.
At that point, on the basis of the climate gases emitted today,
humankind will have used up the allowance that would have
limited the anthropogenic temperature rise to 1.5 degrees
Celsius, as was agreed at the Paris Climate Change Conference in 2015.
A child born today would therefore have to be driven in a
climate-neutral vehicle by the time they start school; learn ina climate-neutral school; live, eat, and play with no negative
impact on the climate. In short: there is not much time left,or as Martin Berger, Vice President Corporate Research andAdvanced Engineering at MAHLE, puts it: “We all need tostep up our efforts. We have to get better every year or we
won’t succeed.”
Effective and open to all technologies
If we want to achieve ambitious goals, we need to act now.
The time for declarations of intent is over, if only because legal
requirements have now come into play, as Nils Dressel notes:“Throughout the EU, a 55 percent reduction in CO2 emissions
compared with 1990 levels has already been agreed for 2030.”
Dressel heads the MAHLE office in Brussels, where he keeps
a close eye on EU legislation. “Since 2020, we’ve seen a lot of
activity, for example through the EU hydrogen strategy, withextensive moves toward the widespread use of hydrogen as
one of the energy carriers for the carbon-neutral future.”

A challenge is always an opportunity. At MAHLE, effectiveness is the guiding principle. “We only do what really has aneffect,” says Martin Berger. That’s why MAHLE continues todevelop all manner of technology that helps to cut emissions:first and foremost, of course, systems solutions for battery
electric mobility. Then there’s the internal combustion engine,which will be powered by both renewable fuels and hydrogen—as will fuel cells. It’s a little like sports: sprinters havedifferent strengths and needs than weightlifters. The situation
is similar for powertrain technologies, which are optimized forenergy efficiency, performance, or endurance, depending on
the application.
MAHLE’s development work ensures that sustainable alternatives that have reached the necessary level of technological maturity can be brought to the mass market. As well as
maintaining the greatest possible breadth and openness to all
the available technologies, the company is especially keen to
foster cross-border cooperation between its various business
units. It’s important to seize every opportunity, because every
gram of emissions saved matters.

“We all need to step up
our efforts. We have toget better every year
or we won’t succeed.”
Dr. Martin Berger,
Vice President Corporate Researchand Advanced Engineering at MAHLE

6Every gram matters

MAHLE supports the development of climateneutral mobility with innovative solutions

The e-compressor: comfort for the
climate. And for the cruising range.
Balassagyarmat/Hungary—The MAHLE plant in Hungary is
located in the northeast of the country, an hour’s drive fromthe capital, Budapest. The production location manager,
Gyoergy Szalay, has been working there for more than twenty
years. He and his team are currently preparing to start producing the next generation of MAHLE’s electric air conditioning compressor. This global endeavor also involves teams
in China, Germany, Slovenia, Spain, and the USA. The market success of MAHLE’s e-compressor shows what can beachieved when interdisciplinary teams work together on the
products of the future.

The e-compressor is the key component in an electrified vehicle’s air conditioning system. It compresses the refrigerant,
thereby ensuring that the vehicle cabin, the battery, and other components are kept cool. “With this component, it’s clearthat we’re making a significant contribution to the acceptanceof e-mobility. Our new, high-performance product keeps batteries cool enough to allow for fast charging in a matter ofminutes,” says Szalay, adding: “Our e-compressor opens up
new possibilities, such as preconditioning when the vehicle
is stationary and operation of the heat pump, which will increase both ride comfort and cruising range.”

PIONIERGEISTMagazine 2021

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“With this component, it’s clear that
we’re making a significant contribution
to the acceptance of e-mobility.”
Gyoergy Szalay,
production location manager, Balassagyarmat/Hungary

In a vehicle powered solely by a combustion engine, the engine drives the air conditioning compressor directly via a belt.
It works less at low speeds, and more at high speeds—nomatter how much cooling is really needed. E-compressors,on the other hand, can be controlled independently and only
operate when they are actually required—thereby saving energy. In an electric vehicle, the compressor also has anotherimportant task: cooling the battery. As charging power increases, more heat is generated in the battery. To help reduce charging times for future electric vehicles, MAHLE was
one of the first manufacturers to focus on developing compressors that provide more power and can function at higher
operating voltages than the products currently available on
the market.
Growing number of customers
The e-compressor project began several years ago; initiallywithin the scope of Thermal Management, it is now handled
by the Electronics and Mechatronics business unit. Today,
MAHLE already supplies its e-compressor to several customers, and start of production is imminent for others. Series
supply to two German OEMs will begin later this year, among
other pro­jects. MAHLE also recorded order growth in China
last year, and the technology group plans to open a new production line there in 2023 to meet the increasing demandin one of MAHLE’s key markets. In order to keep pace withgrowth as regards research and development, MAHLE is
expanding its capacities in Valencia/Spain, in addition to its
established primary development location in Amherst/USA.
The new research and development center will enable MAHLE
to develop its solutions for customers throughout Europe evenmore quickly and directly.

8

The e-compressor also combines several of MAHLE’s areasof expertise. “The electric motor and the appropriate control system, the compressor’s mechanics—we can do it all,”says José Carvalho Gonçalves, Director Operations for theCompressors profit center. According to Gonçalves, one of
the biggest challenges is acoustics. “An electric vehicle isvirtually silent when it’s driven. That means that every soundinside the car is suddenly much more noticeable, including
those made by the compressor.” To set new standards withthe latest generation of the product, the developers therefore
put all the details of the compressor to the test.
“Powerful, efficient, lightweight, quiet, and low-cost—that’s
what our customers expect, and they trust us to get it right,
just as we’ve consistently done for decades where compressors are concerned.”

Every gram matters

Spaghetti vs. lasagna—the flat membrane humidifier
Stuttgart/Germany—The new test and research center, where
MAHLE has been researching new systems solutions for hydrogen applications since March 2021, extends over 1,400
square meters. Components for fuel cells and engines are developed on the test benches. Shiny silver-colored pipeworkruns through the futuristic-looking, laboratory-like workshops,
and there are monitors and measuring stations all around. At
MAHLE’s Stuttgart headquarters, more than 100 experts areworking on future technologies involving hydrogen.
The focus is on developing drive solutions for heavy-duty
commercial vehicles. This segment is where the strengthsof hydrogen technology come into their own; batteries, on
the other hand, are too heavy and too large to be used inlong-distance transportation by truck, even in the long term.
“However, in order to power heavy-duty commercial vehicles

with hydrogen and without creating emissions, innovative
solutions are still required, especially for reducing the weightof the components and increasing efficiency,” says Dr. Peter
Geskes, MAHLE’s global head of development for filtrationand engine and fuel cell peripherals. At MAHLE, several
teams are collaborating on this across business units andlocations. One of the projects is a new membrane design forfuel cells: the flat membrane humidifier.
Behind this complicated name is an innovation that will extend the service life of fuel cells and allow them to be manufactured at a competitive price. Several prominent carmakers
from China, South Korea, Japan, the United States, and Germany are currently focusing on this technology. Peter Geskes
begins by using a culinary image to describe MAHLE’s innovation: “We’ve changed the fuel cell design from spaghetti

PIONIERGEISTMagazine 20219

to lasagna.” So, what does that mean? A fuel cell needs anadequate supply of high-humidity fresh air at all times. If thehumidity level in the fuel cells is too low, this reduces performance and service life. The high moisture content of theexhaust air from the fuel cell is used to increase the humidityof the fresh air being drawn in. After all, a lot of water is produced during the “cold combustion” of oxygen and hydrogen. Moisture is carried from the exhaust air side to the fresh
air side via many tiny membrane tubes. In Geskes’ image,these are the spaghetti.
Instead, MAHLE uses ultrathin membranes, which arestacked in the humidifier to form a block—the lasagna. Exhaust air with a high vapor content passes through half of thelasagna layers. Fresh air that’s drawn in flows through theother half of the layers toward the fuel cell. The membranes
are permeable to water vapor, but not to liquid water andnot to gases. As a result, the dry outside air becomes moist
after passing through the membrane—which is exactly tothe fuel cell’s taste, and it thanks the cook by being efficientand durable. Or in less culinary terms: the more humid theair, the higher the efficiency. But the most important thing isthat the service life of the components is extended. The flat
membrane technology increases the efficiency of the humidifier, boosting its performance. Size and weight can thus be
reduced by up to 70 percent: the lasagna effect.

From idea to research projectWork on the highly effective flat membrane humidifier began
in 2017. In September 2018, MAHLE and its partners embarked on a research project funded by the German Federal
Ministry for Economic Affairs and Climate Action. Michael
Baumann, project manager at MAHLE, says: “I think it would
be hard to find another company that has approached theissue of hydrogen propulsion as thoroughly as MAHLE.” Hepoints out that several different areas of MAHLE expertisehave come into play in the development process, ranging
from thermal, air, and liquid management to filtration andelectronics. Michael Baumann also praises the international
cooperation between the various MAHLE locations: “We
use the feedback from our colleagues in Japan and Korea.
The teams there are fully involved in the work here, which isreally fun and combines a wide variety of perspectives andrequirements.” For example, the seal design was developedin Japan and the manufacturing process in Europe. Series
production of the flat membrane humidifiers is scheduled to
begin next year, and market demand is high.

“We use the feedback from ourcolleagues in Japan and Korea.
The teams there are fully involvedin the work here, which combines
a wide variety of perspectives andrequirements.”
Michael Baumann,
project manager at MAHLE

10Every gram matters

The alternative:
the hydrogenengineThere’s another way hydrogen can help to reduce emissions—one that, until now, has received less attention
outside specialized circles. MAHLE is one of the pioneers
working on hydrogen-powered engines. Because hydrogen
doesn’t contain carbon, it doesn’t release CO2 when combusted, in contrast to traditional diesel and gasoline.
That would constitute a major step toward climate neutrality. Moreover—and this is what’s so appealing about usinghydrogen—the technology can be based on existing drive
systems. That is to say, drives already used in vehicles thatare on our roads today, as Christian Trabold explains: “We
can reuse components and systems from the engine throughthe cooling module and on to the vehicle architecture.” Thehydrogen engine project manager at MAHLE and his teamare engaged in the further development of engine technology
for hydrogen combustion. “In hydrogen combustion, the engine parts are exposed to very different boundary conditions
than when running on diesel,” says Trabold. He continues:“One completely new issue, for example, is hydrogen embrittlement, which can lead to fatigue when hydrogen is introduced into materials.” Another important consideration is thepotential for premature ignition, where the fuel mixture ignites
spontaneously rather than being ignited by the spark plug.
This leads to momentary high peak pressures and, in particular, can damage pistons and rings. More water is produced in
the hydrogen reaction than in the case of conventional fuels,
which in turn can lead to corrosion and oil dilution.”
Option for more power and greater cruising range
Hannes Marlok, another project manager in the hydrogen engine team, is convinced of the potential of this technology:“For very heavy trucks that need to be particularly powerfulor have a long cruising range, as well as off-highway vehicles, the hydrogen engine is the solution. That’s because it
requires less cooling in comparison with the fuel cell and ismore resistant to dust and contaminants.”
There have been initial expressions of intent among sometruck and engine manufacturers to include hydrogen engines
in their portfolios. Hannes Marlok sees MAHLE as a leader inhydrogen engine technology. According to Christian Trabold,there are also synergies for fuel cell development: “For example, we can use the same tank design for both applications.”
The hydrogen engine should be ready to enter series production in 2026. It could therefore be a rapidly deployableoption for reducing CO2 that can quickly make a tangible
contribution to achieving the shared goal of a carbon-neutral
economy.

PIONIERGEISTMagazine 2021

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#StrongerTogether
Take action, don’t wait and see. Tackle problems and don’t give up.
Find solutions, not barriers. In the second year of the pandemic, thepeople at MAHLE showed what “ONE MAHLE” is all about: they took
on social responsibility, stabilized supply chains, ensured smooth
production processes, and actively promoted their colleagues’ health.
These are small stories that represent the big picture.

No standstill
In 2021, the coronavirus pandemic with its regional lockdowns put global supply chains under extreme strain.
In addition, the scarcity of semiconductors aggravatedthe situation. Against all odds, the approximately 900
MAHLE purchasing experts from all over the world went
all out: To procure semiconductors in time, the purchasing, sales, and logistics teams completed business planning almost six months earlier than usual. They transparently traced back the supply chains for production andfound direct solutions with our partners. As a result, allcustomer contracts were fulfilled in 2021. Or as Stefan
Maier, Vice President Corporate Purchasing of the MAHLE
Group, put it:“The fact that there were no
significant interruptions due
to missing MAHLE components at customer plants insuch a year is a phenomenal
achievement by the purchasing and logistic teams
around the world.”
12

100%
convinced

Brazil is one of the world’s countries hardest hit by the corona­virus pandemic. It is therefore important to convince peopleof the vaccine’s effectiveness. The accompanying campaign
was particularly successful in Brazil, thanks to Dr. Ana Paula
Egrejas Esper. What was her key to success? “Inform, inquire,
and inform again. No question should remain un­answered.”
The doctor and health manager of the locations in Brazil andArgentina was the face of the local vaccination campaign, andshe and her team of over 50 employees achieved enormous
results. The health experts provided education via video, telephone, letter, a reminder app, and in many personal conversations. And within a few months, they could convince almost
every one of the approximately 8,000 employees at the Brazilian and Argentinian locations to roll up their sleeves andprotect themselves by getting vaccinated.

#StrongerTogether

Don’t look away
During the coronavirus pandemic, thousands of people in India struggled with hunger. Sanam Harkare from
the MAHLE location in Pune was not willing to accept
this. She, along with support from her husband Suyash,
launched the Replacing Hunger with Smiles initiative.
Sanam Harkare remembers the exact moment when
she realized she had to do something: “It was a hot
day in April 2021, with India experiencing yet anotherstrict lockdown. As we were driving through the streetsnear our house, my husband and I saw a woman lying
dead in the street. She had starved to death!” Sanam
Harkare, who works in the Human Resources team at
MAHLE in Pune, was deeply shaken by this incident.
She wanted to take action and “give something back tosociety,” as she says.
Her idea: a distribution campaign for cooked meals toprovide for those who have been in need because of
the pandemic. Initially, she and her husband financed
the project out of their own pocket. Later, friends, family
members, a non-governmental organization known as
YOUG Foundation and numerous MAHLE colleagues offered support. The group grew rapidly to 25 volunteers.
An Indian delivery service also joined in. “In the beginning, we distributed 100 meals a day. But within a few
days, the number rose to over 1,200 meals per day,”says Sanam Harkare. Additionally, the helpers began
distributing food packages to needy families and widows
who live in Pune’s slums, so that they could be selfsufficient. From April to mid-October, Sanam Harkare
and her team were able to offer more than 50,300 cooked
meals. Grocery kits were delivered to 19,000 families sufficing for three months each.

50,300cooked meals

3,042,074
FFP1 and FFP2 masks have been manufactured by ourcolleagues in St. Michael, Austria as of January 2022. The
production in the plants ran in addition to regular operations during the past year, which proves once again the
Carinthian team’s go-getter qualities and can-do attitude.

Remote?
For sure!
This could happen: an update for a machine in Stuttgart does
not load and the expert from the manufacturer is located inSouth Korea. Since the pandemic, remote service via online
access or smart glasses has been in even more demand. In
view of the record number of cyberattacks worldwide, which
also targeted industry, MAHLE tested the next level of software in 2021. Its name: Direct Remote Maintenance Access.
A highly secure connection to the machine can be established from anywhere.
This is made possible by multilevel security infrastructure
and access that is limited to the duration of maintenance, adefined machine, and the assigned technician. This principle
works in a similar way to VR glasses. A pilot project proved so
successful that the maintenance of machines with VR glasses
is to become the standard for all MAHLE plants worldwide.

PIONIERGEISTMagazine 202113

Keeping acool head
What has been established for decades in the caseof combustion engines has the potential to give the next
generation of electric vehicles an enormous boost in
acceptance: thermal management designed for optimum
performance. MAHLE engineers are using systems
solutions to extend cruising range. And to make surethat the passengers and all drive components feel equally
comfortable.

Vehicle manufacturers and their development partners facea constant paradox: the temperature inside the vehicle always runs counter to the outside temperature. When it’scold outside, people like it to be warm inside, and vice versa.
Up to now, engineers have used waste heat from the combustion engine to heat the cabin. To handle warmer times ofyear, air conditioning systems became standard in almost
every vehicle class. But with the paradigm shift to battery
electric drives, the overall system for regulating heat andcold takes on a new significance.
Dawning of a new age“An electric motor generates virtually no waste heat,” explains Dr. Roger Busch, Vice President Engineering ThermalManagement at MAHLE. But anyone sitting in an electricallypowered vehicle will also expect to enjoy comfortable temperatures—whatever the season. Without efficient thermal
management, it will be difficult for e-mobility to become
established on the mass market, as heating and cooling

14

consume energy, and that’s detrimental to the vehicle’s
cruising range. MAHLE engineers from various disciplines
therefore look at the issue holistically—from the smallest
electronic component through the complete heating circuit.
This systems approach is particularly important because thedemands on modern electric vehicles are constantly increasing: they are expected to charge in minutes, have a rangeof at least 500 kilometers, and offer the customary level ofcomfort. It’s clear from the various challenges that pioneering spirit is essential for MAHLE developers. The most fundamental challenge involves the thermal management of thepowertrain battery. “It’s very similar to us humans in terms of
its comfort factor,” says Roger Busch, putting the concept in
a nutshell. A lithium-ion battery works best in a temperature
window between 20 and 40 degrees Celsius. This meansthat a battery must be heated in winter and cooled in summer—if necessary, at high charging power.

Keeping a cool head

20–40°C
is the temperature window in which
a lithium-ion battery works best.

PIONIERGEISTMagazine 2021

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“The powertrain battery is very
similar to us humans in terms of
its comfort factor. A battery mustbe heated in winter and cooledin summer—if necessary, at highcharging power.”Dr. Roger Busch,
Vice President Engineering Thermal Management at MAHLE

Faster charging
Many drivers are concerned about how long they have tospend at the charging station. Nobody wants to wait unnecessarily, especially on longer trips on the freeway. “We
are seeing today’s charging power levels of between 100
and 150 increasing to 250 to 350 kilowatts,” explains Laurent
Art, Director Predevelopment Thermal Systems and Components. This means that a charging stop at a service station
takes no longer than it does to buy a snack and visit the
restroom. Battery preconditioning is a vital prerequisite fora short “pit stop.” That is to say, the minutes before the carreaches the fast-charging post. The heating/cooling system
ensures that the battery cells are at the optimal temperature,
allowing them to take up the maximum charging power.
“However, charging shouldn’t be thought of as a linear process, where charging takes place consistently at constant
power,” explains Roger Busch. “We talk about a charging
curve.” Depending on how full the battery is, the charging
output begins at a power level that slowly increases to the
maximum during the process. Once 80 percent charging

16

Keeping a cool headcapacity is reached—if not sooner—the battery system reduces the charging power to protect the cells. It can sometimes take just as long to put the final 20 percent of energy
into the battery as it did to charge it up to 80 percent.
This phenomenon can be observed by anyone going to themovies. In a cinema with a capacity of 600, the first 200
guests will find their allocated seats in just a few minutes. It
takes the next 200 much longer. Guests seated at the endsof rows have to stand up to let others past. It takes the longest time to seat the last 200 moviegoers. The same applies
to charged electrons, which have to find a place on the anode of the battery cells.
The heat pump is key
Heating the cabin and the all-important process of conditioning the battery cells both require energy. Because thisenergy comes from the powertrain battery, it’s no longer
available for driving performance. And so the cruising range
reduces, especially in winter. This is where MAHLE makes
use of the heat pump as an integral thermal management
component. In simple terms, it operates in a similar way to
a refrigerator. It uses a refrigerant to extract energy from theinterior, thereby lowering the temperature. The extracted
heat is released to the environment via the back of the refrigerator. The heat pump in an electric car works the otherway around. It takes energy from the outside air and uses it
to heat the cabin. The bottom line is that less energy is takenfrom the battery to run the heating system. The electric car
travels about 20 percent further at an outside temperature of
0°C than it would without a heat pump, while maintaining thesame level of comfort.

Modularization of thermal management
Heat pump, cooling and heating circuit for the battery, airconditioning for the cabin: it’s clear from the list of tasks
that we’re dealing with a complex system with many parts.
“There are a large number of components in the vehicle
needed for thermal management, as well as lines, connectors, and valves,” says Roger Busch. But installation space
is a precious commodity. Also, the fewer components thatneed to be installed during production, the greater the reduction in costs and complexity for the manufacturer. “Ourapproach is based on modularization,” explains Laurent Art.
The different thermal management components are combined in modules that are as compact as possible. Insteadof working with individual wiring harnesses, the fitters working for MAHLE customers only need to install one assembly.
This saves time—in part, because the leakage test on themodule is carried out by MAHLE.

How heat pumps work
Ambient air flows into an evaporator in the front
end of the vehicle where it meets the refrigerant,
which can absorb energy from the air. This causes
the liquid refrigerant to heat up and change froma liquid into a gaseous state. In the next step, acompressor (e-compressor) increases the pressure.
As the pressure rises, so does the temperature of thegas. It releases its energy to the heating system byliquefaction. The refrigerant circuit is closed via an
expansion valve.
Supposing that the outside temperature is 5 degrees
Celsius, the electric heating would have to heat theinterior from 5 up to a comfortable 21 degrees. The
heat pump extracts enough energy from the ambient
air to heat the air directly to 21 degrees in order towarm up the vehicle cabin. This saves energy, whichmeans that the system reduces the loss of range
experienced in the winter by around 20 percent.

Another challenge for developers arises as a side effect ofelectric mobility: noises that were previously drowned out
can suddenly be heard. That’s because the rotor rotates almost silently in the stator in the drive. Passengers may find it
annoying if thermal management components now become
audible. MAHLE engineers therefore have their sights set ona heating and cooling circuit that’s as quiet as possible.

PIONIERGEISTMagazine 2021

17

Rethinking the design of heating and cooling systems goes
hand in hand with a change in thinking in the company itself.
“ONE MAHLE” describes this development best. Business
units such as Thermal Management, Filtration, and Electronics and Mechatronics are bringing their competencies
into closer alignment. After all, modular systems require adifferent approach. As Roger Busch describes it: “A holistic
mindset has been adopted, with all departments considering the whole vehicle.”
Achieving peak performance with intercell cooling
The holistic approach is also helping to address a recent development. The e-mobility industry is currently at a technicalcrossroads. After initially using lithium-ion batteries carrying
400 volts, manufacturers are now introducing 800-volt systems in a growing number of vehicle classes. This has theadvantage of reducing the charging time by increasing thecharging power. For MAHLE engineers, however, it meansthat more waste heat is generated in the battery system,
which has to be dissipated. That’s because the amountof heat generated is equal to the square of the increase incharging power. More effective cooling methods are needed.

Up to now, battery cells have been bundled into modules,
which have in turn been grouped together to form a battery pack. Fixed to the bottom of these packs is a coolingplate, through which lines containing coolant wind. The plate
thereby conducts the heat away from the battery cells. A
crucial point as regards future e-mobility is that, as charging
power increases, it would be more efficient for the coolant
to flow directly around the battery cells. This is exactly what
happens in MAHLE’s immersion cooling system. It’s basedon the principle that the liquid surrounds the individual cells.
Special electrically nonconductive oils are used. As a result,immersion cooling significantly reduces the battery temperature, so it could be the solution to various technicalchallenges, such as faster charging or extending the service
life of the components.
The ongoing development of thermal management technology therefore continues to call for MAHLE’s pioneering
spirit. That’s because the use of solid-state batteries in EVs
is on the horizon, with liquid electrolytes being replaced bysolid materials. This increases the energy density and eliminates the risk of fire in the event of battery damage. However, there will still be a need to control the temperature of
the battery so that it delivers optimum performance. Heating
and cooling thus remain the key technologies enabling the
success of e-mobility.

“Our approach is based on themodularization of components
to reduce cost and complexity
for manufacturers.”
Laurent Art,
Director Predevelopment
Thermal Systems and Components

18

Keeping a cool head

The future—with no energy loss
Thermal management must learn to save: while the combustion
engine’s primary target was to dissipate unwanted heat, every joule
is used as efficiently as possible in e-mobility.

Battery electric drivewith heat pump
The powertrain’s waste heatand the peripheral energy
are used to heat the interior.
This reduces the energy
requirement of the cabin heating. Essentially, a separate
electric auxiliary heater is only
required at temperatures
significantly below the freezing
point (below –10°C).

Electric motor

Heat pump

HeaterPowerelectronics

Battery

Battery electric drive
without heat pump
The waste heat from the
motor, the power electronics,
and the battery is dissipatedto the outside. The energy
for the cabin heater is drawn
from the battery—this reduces
the cruising range.

Electric motor

HeaterPowerelectronics

Battery

Combustion engine
Part of the heat generated
by the engine is used for thecabin heating, but a large
portion is wasted.

EngineIncreasing relevance of efficient use ofavailable energy sources

PIONIERGEISTMagazine 2021

19

Lighthouseproject
in Parma
The location is practically emission-free thanks tostate-of-the-art technology, and the building generates
its own electricity. Then there’s the architecture,designed to inspire customers and staff alike. With its
new Service Solutions center in Parma/Italy, MAHLE
is proving that innovation and climate protection are
mutually beneficial.

When the morning sun shines on Parma, the location in the north of thecity appears to glow. The snow-white facade reflects the light, while thetinted windows and blue MAHLE lettering provide contrast. The newService Solutions center is certainly an eye-catching site in the large
industrial zone of this economic hub in northern Italy. It’s as striking as
a lighthouse—a suitable metaphor for a building that aspires to be a
beacon project for two of the biggest future topics of all. In setting new
standards for MAHLE in terms of climate protection and sustainability,
it’s hoped that the building will serve as an example for other companies too.
After just over a year of construction, the workforce of around 150 moved
into the new headquarters of Group subsidiary MAHLE After­market Italyin spring 2020. This brought the Service Solutions unit’s three locations
together under one roof, on a site covering 15,000 square meters. The
plant develops, produces, and sells diagnostic and driver assistancesystem calibration devices, equipment for air conditioning as well as
emission control and transmission maintenance solutions. Workshop
demand for these digital tools is rising—as reflected in the location’s
dynamic business figures.

20

Lighthouse project in ParmaPIONIERGEISTMagazine 2021

21

“Going green makes an impact—and not only from a climate
perspective. When we spend timein natural surroundings, it has
an impact on our mood.”
Daniele Colzi,Managing Director MAHLE Aftermarket Italy

On entering the building’s lobby, you’d be forgiven for thinking
you’d stepped into a flagship store. Diagnostic tools developed and assembled here in Parma are displayed on shelves.
Alongside them are rows of certificates and a nameplate
bearing the logo of workshop service specialist BrainBee,
which was acquired by MAHLE in 2017 and has operated
successfully in its markets as MAHLE Service Solutions eversince. First-time visitors to the Parma location inevitably findthemselves drawn to this exhibition. Which is precisely theintention: “This should be more than just a workplace,” says
Daniele Colzi, Managing Director MAHLE Aftermarket Italy.
“We want our staff and customers to really enjoy spendingtime here.”Working toward zero emissions
More on the feel-good factor later, but first a look at thebuilding’s green credentials. The location’s energy class is
A+++, the highest possible rating for a property in Italy. To
see how the building has earned such a distinction, we needto start on the roof. The photovoltaic system installed there
currently can meet up to 70 percent of the location’s energy
requirements on sunny days. By further expanding the PV
system in the course of 2022, the site will become independent self-supplier in the medium term even if production isrunning at full capacity and additional heating or cooling isrequired. Not only does this make environmental sense, but
it’s also good for the balance sheet: by the eighth year of operation, the extended photovoltaic system will have alreadypaid for itself.

22

Lighthouse project in ParmaUp to70%of the location’s energy requirements
can be met by the photovoltaic system
on sunny days.

At times when production at the plant is in full swing, the solar power generated on the roof is needed for manufacturing
and in the offices. When the energy demand is lower—at theweekend, during holiday periods, and overnight—the surplus
is sold to the local energy supply company. The income generated is reinvested in sustainability, such as optimizing theenergy system to achieve further efficiency gains. “Obviously,
our goal is to retain our A+++ rating,” says Daniele Colzi.
That’s no easy task, however, as demands are increasing
every year. In other words, there’s no question of the location
resting on its laurels. “But that’s not a problem for us. We’realways looking to improve.”
Moving from the roof back into the plant, the way is illuminated by efficient LED bulbs controlled by a smart sensor-based
system. If no motion is detected in a particular area, the lights
there are automatically switched off to save electricity. The
rooms and halls are cooled and heated with the aid of a heatpump. Natural gas is only needed as a backup when outside
temperatures are very low and heat demand for production
operations is high. As this is seldom the case in Parma, however, there are practically no CO2 emissions associated withheating the building either.
Effective cooling, on the other hand, is a must on northern
Italy’s hot summer days. The building’s air conditioning system cools the walls and ceilings instead of blowing cold air
into rooms. Not only is this technology highly efficient but it
also provides a natural coolness, comparable to the pleasant warmth provided by underfloor heating. The data for thelocation’s smart heating, cooling, and power supply setup
is consolidated in a digital control system. A display showsenergy managers how high the demand is and how efficiently
the system is running—as well as what needs to be tweakedto achieve further optimizations.

A location designed to inspire
But it’s not all about the technology. “Another aspect of sustainability is ensuring people feel at ease in their surroundings,” says Daniele Colzi. Both inside and out, the Parmalocation looks greener than comparable industrial buildings.
It starts on the roof, where staff and customers can attend
meetings in unique, plant-filled outdoor lounges on natural
timber flooring, protected with sunshades. Some 40 trees
grow around the building and green spaces are a key feature,extending over a total area of 1,800 square meters. “Going
green makes an impact—and not only from a climate perspective. When we spend time in natural surroundings, it has
an impact on our mood,” says Daniele Colzi.
This positive effect continues inside: plants serve as partitions in the office areas, where they noticeably improve theatmosphere. To Daniele Colzi, the open architecture with lotsof glass and unimpeded views of manufacturing is a “symbolof the transparency and innovation” that are fundamental tothis building: “This concept is all about blurring the divide
between offices and production.” Customers who come toParma for a business meeting get a direct view of the manufacturing process through the glass facades. “This is our way
of signaling that we see the two areas as one unit.”
In the pleasantly bright production halls, technicians workat large benches, supported by fully automated systems
that are elegance in motion. In training rooms with state-ofthe-art equipment, workshop customers are introduced to
MAHLE’s innovations from Parma. Currently, much of the
training is focused on the TechPRO system, which harnesses artificial intelligence to make maintaining and calibrating
driver assistance systems easier and quicker than ever. Andin case customers crave a perfect espresso afterward, thereis, of course, a café serving the finest coffee here at theParma location.

PIONIERGEISTMagazine 2021

23

“Our industry faces the immense taskof rapidly switching over to alternative
forms of mobility for the sake of theclimate. Innovation and sustainability
will be needed at every level.”

Enrico Breggia,
Advisor to MAHLE Aftermarket

power, we move on to the next—all the way through to establishing a climate-neutral supply chain.” A Pandora’s box,
so to speak? “I think that’s too negative,” says Colzi. “I’dprefer to call it a permanent challenge.”

Daniele Colzi says customers tend to have an unusual reaction when they visit the headquarters of MAHLE Aftermarket
Italy for the first time. Searching briefly for the right term, helaughs and uses an American expression: “Holy cow!” Thenhe adds, “People are amazed and impressed in equal measure.” How can you tell that people feel at ease in a building? “You can see it in their eyes as they enter and leave,”
Daniele Colzi says from experience. “Many employees tellme they’re almost as happy here at work as they are athome.” There simply couldn’t be a bigger compliment for acompany based in beautiful Parma. Obviously, the excellent
coffee and the outdoor rooftop lounges have something to
do with this. “But mainly,” says Daniele Colzi, “it’s because
this building shows how worthwhile it feels to put sustainability into practice.”

With regard to the automotive sector as a whole, the MAHLE
Aftermarket business unit sees itself as a driver of climate
protection. “That’s what we demand of ourselves,” says Enrico
Breggia, “also because it allows us to demonstrate to ourcustomers that we’re at the forefront when it comes to leading the automotive and engine industry into the future.” As anadvisor to MAHLE Aftermarket, Enrico Breggia was heavily
involved in the design and construction of the new Parmalocation. “The basic concept behind the building is to unite
economics and the environment,” he summarizes. “And thatcan only be done with innovative ideas.”“See what we can achieve!”
The Parma location is exceptional—but also essential. “Asa company, we’re committed to meeting our responsibility
to run our business sustainably and do everything we canto reduce our carbon footprint as much as possible—with
the aim of making our Parma site climate-neutral,” says
Daniele Colzi. Although this target has been all but reachedalready, he knows it’s just one more step, describing climate
protection as an issue with enormous depth. “As soon as
we achieve one objective, such as generating all of our own

This is true for the Parma location and the automotive sector
as a whole. “Our industry faces the immense task of rapidly
switching over to alternative forms of mobility for the sakeof the climate,” observes Enrico Breggia. He notes that thisnot only means vehicles with different drives but also completely new business models and customer relationships.
“Innovation and sustainability will be needed at every level,”comments Enrico Breggia, getting to the heart of the matter.
By way of example, he refers to a device developed in Parmafor analyzing the performance of vehicle air conditioning systems. “This development guarantees efficiency in the car,”says Enrico Breggia. “So it’s only natural that we should
demonstrate MAHLE’s air conditioning expertise here in thisbuilding as well.” Accordingly, the Service Solution center
serves as a brick-and-mortar calling card: “This location
sends out a clear message: see what we can achieve!”24

Lighthouse project in Parma

Open design, lots of light: the building stands
for sustainability in practice, transparency, andinnovative thinking. Indoor and outdoor areas
are an invitation for employees and visitors aliketo exchange ideas.

PIONIERGEISTMagazine 2021

25

“Sustainability is
all-encompassing”
Kathrin Apel has been Global Head Sustainability & HSE
at MAHLE since early 2021. In this role, she is responsible
for the company’s sustainability management system,
which covers occupational health and safety and environmental management in addition to climate protection.
She explains where MAHLE stands in terms of sustainability—and the benchmarks it wants to set.

Ms. Apel, what are your views on the current status ofsustainability in the corporate strategy?

What are they?

As suppliers to the automotive industry, we are setting sustainability benchmarks with our ideas and targets. This ishappening on two levels. Firstly, new technical developments
target efficiency and sustainability, and are particularly aimed at
protecting resources and the climate. Secondly, we operate ina way that supports the measures and our economic stability.
We have high ambitions when it comes to climate protection:
our global manufacturing will be carbon-neutral from 2040
onward. And we can be proud of ourselves, because we’vealready made our German plants climate-neutral.

Firstly, we’re increasing the amount of electricity we generate ourselves. We carried out two reference projects withphotovoltaics in Parma/Italy and Montblanc/Spain in 2021.
We want to build another eight PV systems in 2022. These
projects are not only reducing our emissions but also increasing our independence from the volatile energy market
as a result of self-generation. Other measures relate to theenergy efficiency of our locations, which we aim to improveby at least 2 percent each year. The third topic area includes purchasing carbon-neutral electricity and offsetting
remaining emissions.

How will this be achieved?

Who or what is driving the company on this issue?

We’re motivated and driven by having a specific target—2040
is not far off. And the first milestone is set for 2030, when we
aim to have reduced our CO2 emissions by at least 55 percent compared to our 2018 emissions. We’ve drawn up an
ambitious road map comprising three key points.

Most of the momentum comes from within the company
itself. But we’re also motivated by the demands and expectations of our stakeholders—especially those of our customers. Our employees also want to work for a company
that operates sustainably.

26“Sustainability is all-encompassing”

An important point for me in this context is that, on joining
MAHLE in January 2021, I quickly realized that the company already had wide-ranging experience in sustainability
matters. Aspects such as energy efficiency and environmental protection as well as good working conditions andoccupational safety have long been key issues in MAHLE’splants. Our success in these areas, today and in the future,is also a result of the good work already carried out in thepast. MAHLE understands sustainability management—eventhough it might have been called something different a few
years ago.

“Our success in theseareas, today and in the
future, is also a resultof the good work alreadycarried out in the past.”

Why is it important to continue to pursue sustainability
proactively?
This allows us to build awareness, create momentum in thisarea, and inspire new ideas. Every system needs a freshboost from time to time, and we recognize that this has anespecially big impact if we don’t have to start from scratch.
Our employees have a strong intrinsic motivation to think andact effectively and sustainably.
Sustainability goes beyond climate protection—what are
your other areas of focus?
Our CO2 road map is a key element of our sustainability management, but you’re right: there’s more to it. With regard to
our suppliers, we are implementing a system that enables
us to track sustainable purchasing and compliance with human rights worldwide. The new Supply Chain Due Diligence
Act gives us a legal basis for this. Because our employees
are important to us, we want to make further sustainable improvements to occupational safety. We’re also committed toincreasing the proportion of recycled materials that we use.
It’s vitally important to me that these sustainability issues are
not viewed in isolation from each other. When we think andact sustainably at MAHLE, synergies are created. This meansthat the initiatives are mutually reinforcing, which benefits us
as a company and our employees just as much as it does ourcustomers and the environment. That’s why I believe sustainability is all-encompassing.

PIONIERGEISTMagazine 2021

27

Declaration of
independence
Until now, powerful and efficient electric motors haveoften employed magnetic materials based on rare earth
elements. A new concept from MAHLE for contactless
power transmission is making a contribution to sustainablee-mobility by maximizing motor efficiency without any
permanent magnets whatsoever.

Zero physical contact, yet always connected: while this may
have become a familiar approach for many of us during thecoronavirus pandemic, it’s actually a well-established principle in power transmission. Known as induction, it involves
transferring alternating current from one coil to another via apulsating magnetic field and is behind the technology thatallows batteries in toothbrushes, smartphones, and sometimes even electric cars to be charged wirelessly. MAHLE is
now using the principle of inductive power transmission to
revolutionize the electric drive. The method makes it possible to selectively energize, and thus magnetize, the rotor ofan electric motor. In a stator that’s also supplied with anelectrical current, this produces the powerful rotational motion that ultimately presses vehicle occupants into theirseats right from the off.

achieved by permanently excited electric motors, which is
why you’ll find them in many sporty vehicles.” The core of
the rotor in these machines contains magnetic materials,
principally neodymium and dysprosium, which belong to therare earth group of elements. Although these metals aren’t
actually rare, their mining and further processing is concentrated in just a few regions. “During the coronavirus crisis, if
not before, the automotive industry has learned that
one-sided supply chain dependencies are better avoided,”reports Berger.

Less dependence in supply chains
To help explain the benefits of the new motor, Martin Berger,
Vice President Corporate Research and Advanced Engineering at MAHLE, provides some background: “The greatest power density at a very high level of efficiency is currently

No slip or wear
Although there are already alternatives, these too have disadvantages. Take the asynchronous motor, for example, inwhich the rotor runs somewhat slower than the magnetic
field produced by the stator. This difference, known as slip,
leads to lower efficiency, at least at low and medium rotational speeds. Then there are magnet-free synchronous machines—two of the best-selling electric cars in Europe in thelast decade use this principle. However, the current in thesemass-production motors is transmitted to the rotor through28

Declaration of independence

4
5
3
2

1

The heart of the motor is the contactless transmitter: therotor is supplied with energy (1) via an alternating field,
which is then converted into direct current (2) for themagnet coils.

These magnet coils (3) replace the permanent magnets.
They induce a magnetic field (4) in the air gap and cause themotor to generate torque (5). Depending on the operating
point, this field—in contrast to permanent magnets—can becontrolled easily in its magnitude.

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29

“We’re convincedthat we’re on the righttrack with our tech­­nology for the next
generation of electricmotor platforms.”
Dr. Martin Berger,
Vice President Corporate Researchand Advanced Engineering at MAHLE30

Declaration of independencesliding contact. Where there’s sliding, there’s friction, andfriction not only decreases efficiency but also almost inevitably leads to wear over time—disadvantages that are avoided
with the contactless power transmission technology patentpending by MAHLE.
Preparing for the e-future
Once the idea was formed, Berger and his team began by
spending around two years working on countless computer
simulations and then on secret laboratory and bench tests.
They had both the expertise and the test equipment, as
MAHLE has long been developing and producing electric
drives for practically everything that moves—from e‑bikes topowerful sports cars. Finally, the results were officially presented in spring 2021. The prototype, a 140-kilowatt unit,
has already demonstrated outstanding efficiency. Up to 96
percent of the current supplied is converted into mechanicalenergy. Even more importantly, an efficiency of at least 95
percent is achieved in large areas of the operating map used
for road travel. As might be expected, the feedback from
customers has been incredible, with dozens of vehicle manufacturers looking to speak with the MAHLE experts. MAHLE
is now in discussions with several customers regarding series production, which may begin in 2025. Berger sees further opportunities: “We’re convinced that we’re on the righttrack with our technology for the next generation of electricmotor platforms due to go into series production in the second half of this decade.”

However, MAHLE is not pursuing an all-or-nothing approach.
Although the company is able to develop and produce complete electric drives, European automakers in particular are
making use of their own electric motor production facilities toensure that existing plants can still be utilized to capacity as
sales of vehicles with combustion engines decline. “We still
consider ourselves a technology supplier,” says Berger, explaining the business model. In practical terms, this meansthat customers can only purchase the core component—theinductive current transformer. A third option may be the most
attractive for some manufacturers, with MAHLE supplying
the complete rotor together with the mechanically connectedcurrent transformer.
Big picture concept
From a technical perspective, there’s a crucial advantage toviewing the rotor and current transformer as one unit: a motor’s performance also depends on how efficient the resulting
heat can be dissipated. “A design that takes account of all ofthese factors provides optimal cooling at minimum expense,”says Berger. The preassembled rotor and current transformer module can also be easily inserted into the stator as acomplete unit at the customer’s motor production facility,
thereby saving on installation and logistics costs.
Although there’s still a long way to go before series production, the path is so clearly mapped out that Berger’s team isalready working on the finer points. Such as how to use acountercurrent pulse to demagnetize the rotor as quickly as
possible in the event of an emergency. Or how an 800-volt
version of the motor, originally designed for 400 volts, might
look. Clearly, the switch to e-mobility in no way marks theend of the story of technological progress. On the contrary,
the sustainable magnet- and wear-free synchronous motor
from MAHLE heralds the start of a new era of evolution.

PIONIERGEISTMagazine 2021

31

You neverstop learning
The automotive industry is not only undergoing a
rapid transformation in terms of technology. The
necessary skills and working methods are also
constantly evolving. MAHLE offers its employees
worldwide the opportunity to expand their skill
set in order to remain an active part in the transformation of the mobile future.

“Shaping MAHLE’s future through goal-oriented and tailormade training—this is our ambition. That is why we arecontinuously developing our learning and qualification programs and establishing new formats and tools that makelearning more flexible,” says Julia Kuntnawitz, Head of Corporate Personnel Development at MAHLE. Lifelong learning
is an essential part of MAHLE’s corporate philosophy. And
needs-oriented training to acquire new skills and expertiseare a focal point of human resources development. Throughout the world, more than 70,000 employees at 160 locations can participate in a comprehensive range of advanced
training courses, in person and digitally, locally and globally,
with a choice of more than 200 global topics, which areconstantly updated and expanded to help all employees be
forward-thinking and meet the demands of the new mobility.

32

MAHLE needs committed and well-trained employees with
the necessary skills and competences within the company inorder to successfully deal with the future transformation in
the industry. In the future, the company will focus even moreon identifying and promoting talent at an early stage, and willthus intensively support the development of new qualifications and skills. That is why MAHLE is investing in selected
measures and instruments that support continuous development as well as in vocational training and part-time study
courses. Committed and curious—that is the common motivation of MAHLE employees.

You never stop learning

“These first few steps
within the frameworkof the Transformation
Road­map made me
hungry for more. I wantto acquire more tech­nical skills and more
knowledge.”
Rafał Sperling, 42,head of Liquid Cooled and Electric Heat Exchangers in
Ostrów/Poland

When MAHLE acquired the thermal management businessfrom automotive supplier Delphi Automotive PLC in Ostrów
in 2015, Rafał Sperling, then a global engineer, was part of
the transformation team tasked with combining expertisefrom both companies to bring the best possible products tomarket. During a conversation in Stuttgart following the takeover, it quickly became clear that he would lead the newteam in Ostrów that would be responsible for the development of liquid heat exchangers. “A job for which my previous
work and studies were not sufficient,” comments Rafał Sperling. “I have more of a mechanical background. I started out
as a stamping engineer, and electronics and electrics were
only touched on in my studies.” During the annual discussion
with his supervisor, he spoke about how he could prepare
himself for the future.
Last year, he participated in Transformation Roadmap—a
global qualification initiative. The purpose of this program isto proactively qualify employees for new or changed roles in
our future business areas such as e-mobility. “What was particularly valuable to me during the training, was the lively discussion with a German professor about what can go wrong
during production and even during product planning,” says
Rafał Sperling. “These first few steps within the framework of
the Transformation Roadmap made me hungry for more. I
want to acquire more technical skills and more knowledge.”
He also took part in the Leadership Training initiative. “ThereI learned how to deal with myself and be a good moderator
for my team,” he says. He is currently one of the regional
talents that are being promoted as a potential global executive. What helps him to manage all of this? “I’ve been doing
karate for 35 years. This helps me to remain focused on andcommitted to what I want to do. Karate is important for mypersonality and my inner strength.”

PIONIERGEISTMagazine 2021

33

“When you’re passionate
about your job, you also
want to tackle the unexpected problems, andlater you can rejoiceover the solutions found.”Patricia Ducatti Miguel Medeiros is the woman who pulls all
the strings for mechanical compressors in Brazil. She is responsible for all new projects in Brazil. Her responsibilities: tomanage and control the projects from the acquisition to theend of production, and to communicate with the customers.
Her daily challenges: “Talking, negotiating, rethinking, andfinding solutions that everyone is satisfied with,” she says.
“I’m the customer’s eyes in project development.” After
studying mechanical engineering in 1994, she started her career in the logistics sector. She later became a project manager for various companies, and since 2005 she has been in
the automotive industry. At MAHLE, she took part in a Future
Leaders Training course. “The interchange of experience wasgreat,” she notes. For her, however, lifelong learning boils
down to daily learning. “I continually have to update my technical know-how, struggle with time management, and deal
with different people. When you’re passionate about your job,
you also want to tackle the unexpected problems, and later
you can rejoice over the solutions found.” She sees herself asa kind of facilitator for her group. “I don’t keep the knowledge
I acquire during training to myself. I share it with everyone. I
want my team to shine.”

Patricia Ducatti Miguel Medeiros, 50,
project manager in Jaguariúna/Brazil

34

You never stop learning

Having his dream job, but still wanting constant change—that
could be the headline for MAHLE employee Sven Fleischer’s
professional life. Ever since his internship while studying automotive engineering, he has been passionate about thecompany. He says: “My enthusiasm for the company has
never left me.” In 2007, after completing his studies, he started working in the acoustics testing department. Two and ahalf years ago, he saw an advertisement for a part-time master’s program in mechatronics, for which he successfully applied. “I supervise the electrodynamic vibration test benches,
so I work with electronics a lot. As a research engineer, it was
clear to me that there will be many new developments in the
future, so I wanted and needed to continue my training.”“As a research engineer,
it was clear to me that
there will be many new
developments in the
future, so I wanted and
His application is successful. MAHLE offers him and otherneeded to continue
co-workers the opportunity to study on a part-time basis. As
part of the Transformation Roadmap project, MAHLE asmy training.”
sumes 100 percent of the tuition fees. Furthermore, lectures
take place within working hours. The Works Council organized rooms for the students to meet in study groups andhelp support each other learn.“In the beginning, it was a big
adjustment to learn permanently again,” says Sven Fleischer.
It’s a life in the fast lane with hardly any free time: He will soon
become a father for the second time, and wants to complete
his studies with the submission of his master’s thesis. Then
he intends to continue doing what inspires him every day:
“Combining theory and practice at work, learning and growing
as new products are developed, and never stop learning.”

Sven Fleischer, 39,
research engineer vibration testing in Stuttgart/Germany

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35

“I want to bring people at
MAHLE together andmotivate them—irrespectiveof their gender, identity,
nationality, language barriers,
ideology, or religion.”
Changzhong Liu, 50,
Director Corporate Purchasing Asia in Shanghai/China

Changzhong Liu was one of the first members of the Global
Talent Circle, a worldwide MAHLE initiative for the ongoingdevelopment of top executives which includes modules in
Brazil, China, and Germany. For two years, the selected talents with different functions and cultural backgrounds met
around the world, in order to prepare themselves for theworking world of the future and learn about leadership, thedifferent MAHLE locations, and the local markets. “For example, we flew to Brazil to see, among other things, how
they work together and what contribution MAHLE makes tothe community there,” says Changzhong Liu, who started

his career as a product engineer in 1996 and joined MAHLE
in his current position in 2014. He was thrilled by the teambuilding: “We spoke very openly about our roles and thechallenges we face, and we formed strong bonds. We arestill in contact even though the program has ended. We help
one another apply what we have learned, we congratulate
one another on our birthday, and we sometimes go out when
we meet at one of the locations.” His goal after this global
exchange of experience: “I want to bring people at MAHLE
together and motivate them—irrespective of their gender,
identity, nationality, language barriers, ideology, or religion.”36

You never stop learning

“I felt that I could improve my negotiation
skills. In the training
course, I learned how
to address my teameven better and how
to identify problems
and solutions.”
Ariane Celisca Gonçalves Araújo, 32,
project manager in Mogi Guaçu/Brazil

Her supervisor Bruno De Aguiar describes Ariane Araújo as aperfect example of someone who can handle numerous problems at the same time. She has worked at MAHLE in the fieldof customer project development for more than 15 years andhas been the matrix team leader of the product development
process since 2017. As a project manager, she ensures thatschedules are adhered to daily, assesses risks and opportunities together with the team, controls the budget, guarantees
quality and delivery, and keeps in touch with customers. “But
I felt that I could improve my negotiation skills,” says Ariane
Araújo. She thus participated in the Mindset Negotiations
training course. “There I learned how to address my teameven better and how to identify problems and solutions.”
And since she is the mother of a four-year-old son and usually works remotely, she was also nominated as a regional
manager for the Female Leadership program in South America. “I learned strategies on how to solve problems even when
I’m not able to go to the other person’s desk. I learned how togive constructive feedback digitally. And I learned about thebest way to balance work and family as a manager.” She saysthat her greatest motivation is that MAHLE trusts her to juggle
and meet all the different demands on a daily basis. “It’s nice
to work in an environment where people believe in you.”PIONIERGEISTMagazine 2021

37

Highlights
2021
Exciting projects, new product solutions,and promising collaborations—despite all
the challenges, there were many highlights
for MAHLE in 2021. Here’s a brief overview
of just a few of them.

progressive
MAHLE sets the pace in 3D printing: in June 2021,
MAHLE opened a new center for additive manufacturing processes in Stuttgart, where complex
components for the production of prototypes canbe manufactured in just a few days. This significantly accelerates the development of components
for electric vehicles and other climate-neutral drive
technologies in the fields of thermal management,
mechatronics, and electronics.

38

Highlights 2021

preventive
Vaccination for our future: in many parts of the MAHLE
world, including Austria, China, Germany, India, Japan,
Mexico, and Slovakia, MAHLE employees were vaccinated during company vaccination campaigns. Until
summer 2021, more than 13,000 members of staff hadtaken advantage of this opportunity, sending a clear
message in support of the fight against the coronavirus. At some locations, the vaccination offer was
extended to family members of MAHLE employees.

effective
Calibration of driver assistance systems in under a minute: this is now possible with the TechPRO® Digital
ADAS 2.0 from MAHLE Aftermarket. Innovative keystone
technology allows workshops to align vehicles with thecalibration frame much more quickly by fully automating
the calibration process. Other benefits of the product include cost-effective use and intuitive operation.

productive
Since April 2021, around 70 engineers have been developing solutions for alternative drives at MAHLE’s
new electronics and mechatronics development
center in Changshu/China. The team is also working
on charging solutions for electric vehicles as well as
thermal management applications for alternative
powertrains. Thanks to this new development center,
the MAHLE Group is further expanding its systems
expertise with the electric powertrain as well as electronics and mechatronics.

PIONIERGEISTMagazine 2021

39

alternative
Hydrogen—an important technological building blockfor the mobility of the future: components for fuelcells and engines are put through their paces at the
MAHLE hydrogen test center in Stuttgart/Germany,
which opened in March 2021. The goal is to develop economical and robust systems solutions for the
automotive industry—with a focus on heavy-duty
commercial vehicles. In July 2021, MAHLE strengthened its commitment to the field of hydrogen technology when it joined the New Vehicle and System Technologies funding program, initiated by the German
Federal Ministry for Economic Affairs and Climate
Action.

In 2021, MAHLE received around 75 awards for innovation, technology, quality, and customer service from renowned customers, partners, and other stakeholders.

positive
MAHLE adopted a new approach at the IAA Mobility: while theGroup presented its promising and sustainable mobility concepts to trade visitors in the halls of Munich’s exhibition center,
MAHLE’s mobility solutions were also on display to the generalpublic in the Open Space in downtown Munich. This allowed
many automotive engineering enthusiasts to experience MAHLE
technologies for the mobility of the future up close and interactively. Offering exciting insights into the Group’s development
work, the MAHLE Mobility Talks were a special highlight of theshowcase in Munich’s city center. The talks were streamed via
the MAHLE YouTube channel and achieved good coverage
within a short time.

interactive
40

Highlights 2021

collaborative
MAHLE Powertrain, the development service provider ownedby the MAHLE Group, supports Liebherr Machines Bulle SA indeveloping hydrogen-fueled internal combustion engines. The
MAHLE Jet Ignition (MJI) prechamber ignition system developedby MAHLE Powertrain plays a particularly crucial role here. By
using this technology, the mixture of hydrogen and air can beignited and burned at a high compression ratio, which makes
the combustion process very efficient. The collaboration aims
to promote the use of hydrogen generated from climate-neutral
processes in heavy-duty and off-road applications.

In 2021, MAHLE was externally rated for the first time and wasclassified by the rating agency Moody’s as Ba1 with stable outlook. This assessment confirms the Group’s financial standing
and corporate strategy. The rating also strengthens MAHLE’s
position on the international capital markets and makes it more
attractive to investors.

competitive
As a partner to the German federal state of BadenWürttemberg, MAHLE is presenting its products atthe World Expo, which opened its doors in Dubai
on October 1, 2021. The company’s exhibit focuses on integrated modular and systems solutions fore-mobility applications. The highlight of MAHLE’spresentation is a magnet-free electric motor that
does not require rare earth elements and is thus
highly sustainable, efficient, and wear-free. Visitors
can also find out about MAHLE’s activities in thefields of battery cooling, technologies for pedelecs,
and electric vehicle charging.

attractive
PIONIERGEISTMagazine 2021

41

Imprint & contact
Published by
MAHLE GmbH
Pragstraße 26—46
70376 Stuttgart/Germany
Phone +49 (0)711-501-0
www.mahle.com
info@mahle.com
Contact
MAHLE International GmbH
Corporate Communications/Public Relations
Pragstraße 26—46
70376 Stuttgart/Germany
Phone +49 (0)711-501-12506
Concept and design
3st kommunikation GmbH
Taunusstraße 59—61
55118 Mainz/Germany
www.3st.de
info@3st.de
Text
Dirk Böttcher
André Boße
Beatrix Gerstberger
Robert Habi
Dirk Kunde
Johannes Winterhagen
Photography
Dirk Bruniecki, Andreas Pohlmann, Wolfram Scheible,
Manuel Uebler, Kerstin Wille, MAHLE Archive
Illustration
Blagovesta Bakardjieva/carolineseidler.com
Translation
Target Languages GmbH
Waldhofer Straße 102
69123 Heidelberg/Germany
www.target-languages.com
info@target-languages.com
Print
ELANDERS GMBH
Anton-Schmidt-Straße 1571332 Waiblingen/Germany
www.elanders.com/ger
info.GERMANY@elanders.com© 2022 MAHLE GmbH,
00007859 EN 2.0.4/22

42

MAHLE worldwide

Around 160
production locations

12 major research &development centersworldwide

More than 71,000
employees*

North America

Europe28 production locations
13,416 employees*

64 production locations
31,909 employees*

Canada, Mexico, USA

Austria, Bosnia and Herzegovina, Czech Republic, France, Germany,
Great Britain, Hungary, Italy, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Turkey

South America

AfricaAsia/Pacific

8 production locations
8,736 employees*

2 production locations
855 employees*

63 production locations
16,382 employees*

Argentina, Brazil

South Africa

China, India, Indonesia,
Japan, Philippines, Singapore,
South Korea, Thailand* As at December 31, 2021

mahle.com