Valeo Czechowice-Dziedzice: Accelerating Electrification with Industrial Innovation

Kinga Kuzma-Bielenin, the Senior Site General Manager, has been at Valeo Czechowice since the beginning. “I have witnessed an incredible transformation of our site,” she says. “We have evolved from producing electrical wiring harnesses into a modern manufacturing plant specialized in advanced electrification technologies. Along the way, we have introduced new tools, automation, and digital solutions that have significantly improved our performance and competitiveness.”

Adding to its manufacturing portfolio, the site is accelerating its transformation into an innovation hub with the expansion of its Research & Development (R&D) footprint and the deployment of the highly agile, modular Metamorph production line.

A Powerhouse for Electrification Technologies

The Czechowice plant has earned a reputation for manufacturing excellence, serving as a critical supplier for global automakers navigating the shift to electric and hybrid powertrains. A few of the key components in the site’s comprehensive production portfolio include:

• eAxle systems: The high-efficiency driving force behind modern electric vehicles (EVs).
• Starters: Providing robust, reliable starting power and mild-hybrid assistance.
• Superchargers: Driving thermal and air-management efficiency to optimize overall powertrain dynamics.
• Electrical Compressors: Powering high-efficiency cabin HVAC and active battery thermal management to optimize EV range and system lifespan.

The Czechowice site has been a consistent contributor to innovation at Valeo with several key achievements over the years, including:

• Launching waste-reduction process for remanufacturing electrical components to advance the circular economy.
• Developing and launching manufacturing of the first Stop/Start system.
• Developing, prototyping and manufacturing industrialization of high voltage e-motor for range extension system for a top German automaker’s first EV.
• Manufacturing the PACE Award-winning electric supercharger to boost engine performance.
• Launching high-volume robotized manufacturing process for high-voltage drivetrain e-motor for premium customers.

“It’s always rewarding to watch an idea evolve from the development phase into full-scale manufacturing and become a product that creates value for our customers,” says Kinga Kuzma-Bielenin. “Every new launch brings fresh challenges, drives innovation, and strengthens our site’s capabilities.”

Metamorph: The Future of Modular Manufacturing

The Valeo Czechowice site is writing its next chapter of manufacturing innovation. To meet the shifting demands of the automotive landscape, automotive suppliers must be as adaptable as the software running inside the vehicles. To achieve this, Valeo has introduced its cutting-edge Metamorph production line at the Czechowice facility.

Unlike traditional, rigid assembly lines dedicated to a single product, Metamorph relies on a highly flexible, modular architecture. This allows the factory to switch between different component variations seamlessly, scale production volumes dynamically, and integrate new technological upgrades with minimal downtime.

This manufacturing agility keeps production highly cost-effective while ensuring Valeo can pivot rapidly alongside evolving client specifications.

Powering the next generation of electric Light Commercial Vehicles

The ultimate proof of the Metamorph line’s capability is its newest milestone: the production of the advanced integrated “combo” unit for a major OEM’s future electric Light Commercial Vehicle (LCV) applications.

Valeo’s Czechowice site plays a pivotal role in this new generation of electric Axle project:

• Smart Integration: The “combo” unit consolidates complex power electronics and drive components into a singular, space-saving package. This reduces overall vehicle weight and maximizes valuable cargo space for urban delivery fleets.
• High Vertical Integration: In-house development and production of the eMotor, Inverter, Reducer, and Park-Lock with Smart Actuator.
• Accelerated Launch: Utilizing the modular Metamorph line allows Valeo to bridge the gap between initial prototyping and high-volume industrialization swiftly.

Scaling Up: Expanding On-Site R&D Facilities

Great manufacturing cannot exist in a vacuum, it requires continuous engineering insight. To support these highly complex e-mobility programs, Valeo is significantly expanding its R&D facilities at the Czechowice site.

By bringing design, simulation, and testing engineers into the same ecosystem as the physical production lines, the site creates a rapid innovation loop. The expanded R&D hub focuses on hardware-in-the-loop (HIL) testing, software validation, and the optimization of power electronics. This ensures that every eAxle, combo unit and other technologies rolling off the line has been stress-tested and validated to meet the highest performance and safety standards.

Circular Economy Hub: Remanufacturing at Valeo Czechowice

Beyond original equipment manufacturing, Valeo’s Czechowice facility serves as the group’s global Remanufacturing Competence Center. By giving end-of-life components a “second life,” the plant spearheads Valeo’s circular economy initiatives under its 4R strategy (Robust design, Repair, Remanufacture, Recycle) to reduce resource consumption and carbon emissions.

• Global Operational Model: As the central hub for remanufacturing, Czechowice standardizes and tests industrial reconditioning workflows, rolling out best practices to Valeo’s other sites worldwide.
• Core Product Families: The facility specializes in disassembling, cleaning, repairing, and re-certifying core electrical and mechanical components, such as starters, alternators, compressors, and clutches. Products are brought back to original equipment (OE) quality standards before re-entering the market.
• Innovative Electrification Technologies: The site pioneers the remanufacturing of advanced e-mobility components, including Electric Drive Components (EDC) and eMotors for major OEMs, extending the lifecycle of complex high-voltage drivetrain systems to support the automotive industry’s EV transition.
• Micromobility Expansion: Demonstrating versatility beyond traditional automotive applications, the site handles circular maintenance for micro-mobility solutions, including the remanufacturing of electric bicycle motors and batteries (e.g., for Paris’s Vélib fleet).
• Environmental Impact: By keeping existing components in circulation, Czechowice’s remanufacturing processes save up to 80% of raw materials compared to producing new parts, substantially lowering the lifecycle footprint of vehicle maintenance.

Shaping the Tomorrow of Mobility

Valeo Czechowice’s incredible growth, according to Kinga Kuzma-Bielenin, is owed to its people.

“I am most proud of our people and their willingness to embrace new challenges. Over the years, I have seen our teams continuously adapt to change, learn new skills, and successfully manage complex projects and transformations,” she says. “Their commitment, resilience, and teamwork have been the driving force behind our success.”

From localized R&D breakthroughs to a modular assembly setup changing the rules of factory flexibility, Valeo Czechowice is creating the blueprint for a smarter, more sustainable automotive manufacturing. By delivering integrated solutions for zero-emission utility fleets, the Polish facility is helping ensure that the future of transport is both electrified and intelligent.