Hirschvogel Marksuhl

In recent years, Hirschvogel Marksuhl has played an active role in managing the far-reaching transformation of the automotive supply chain. The increasing importance of e-mobility, CO₂ reduction and lightweight construction has significantly reduced the demand for conventional steel components. For a site whose core expertise and infrastructure had been focused on steel forming for many years, this represented a significant turning point.

Against this challenging backdrop, the need for clear transformation emerged. In 2023, the Marksuhl site developed the Strategy 2030 through a series of intensive workshops, building on the market opportunities identified in the ‘European Footprint 2022’. Despite the profound shift in the market, the top priority was to secure Hirschvogel’s long-term competitiveness – and thus employment – in Marksuhl.

The transformation goes beyond isolated optimisation measures and focuses on the strategic reorientation of the entire site. The key enablers include the conversion of existing steel presses for new aluminium applications and their realignment along the value streams. The technological transformation at Hirschvogel Marksuhl involves much more than a simple reaction to the market environment. One example of how the site is using this transformation to set new standards in the market is the globally unique, fully interlinked aluminium long-part press.

The transformation is following a consistent roadmap. By 2026, the systematic alignment of operations around the value stream will be complete. Material handling distances and lead times have been radically reduced through space rationalisation, layout optimisation and material flow optimisation. The Lean Roadmap's more than 25 improvement projects are driving continuous performance improvements. Together these activities will culminate in a production system that is firmly rooted in Lean principles and digitalisation.

The consist integration of Lean management and digitalisation has provided additional momentum to the transformation. Many of the smart factory web apps developed in-house by Hirschvogel, including those for tool management, root cause analysis, digital shift logs and maintenance, support day-to-day operations. Systematically connecting   production equipment to the MES ensures the data availability and transparency required for these applications.

Hirschvogel Marksuhl has achieved quantifiable and verifiable success in its transformation. It turned the crisis into a strategic opportunity by successfully implementing a lean transformation while utilising existing structures, stabilising employment and establishing itself as a technology leader in the market. Annual turnover in the aluminium sector is set to rise from around €89 million in 2025 to around €160 million in 2028. The jury was proud and pleased to award Hirschvogel Marksuhl the ‘Lean Transformation 2026’ Special Award.

Headquartered in Denklingen, the Hirschvogel Group is one of the world’s largest manufacturers of mass-produced and further-processed steel and aluminium components for the automotive industry. Its components are used in nearly every vehicle, contributing to greater efficiency, enhanced safety and reduced emissions. Operating eight facilities across three continents, the group employs approximately 6,200 people and generate annual revenues of around €1.3 billion.

Employees
Ca. 6.200 worldwide

Revenue 2025
€1.3 billion (whole group)

The plant
Marksuhl, located in Thuringia, is one of the Hirschvogel Group’s production sites specialising in the manufacture and further processing of precision steel and aluminium components. These components are used in powertrain and chassis applications, as well as internal combustion engines and e-mobility systems, in the automotive industry.

Address
Dr.-Manfred-Hirschvogel Straße 1
99834 Gerstungen
Germany

Products

• E-axle components
• Gear wheels
• Steering and chassis components
• Aluminium forgings for internal combustion engines and electric vehicles

Employees
around 580

Revenue 2025
€180 Mio.