Home Turf Advantage: KION’s Expansion Strengthens South Carolina Manufacturing

Members of the OpExChange network visited KION North America’s Summerville campus on November 4th for an immersive look at one of South Carolina’s most capable manufacturing operations. Leading the visit was Daniel Schlegel, Vice President of Operations, whose decades of experience – and genuine enthusiasm for the craft – shaped a thoughtful, people-focused conversation.

KION North America operates as part of the global KION Group, a leading manufacturer of industrial trucks and material-handling solutions under well-known brands such as Linde and Baoli. While the company has a global footprint, Daniel emphasized that Summerville holds a unique position in their North American strategy: “This is Home Turf.”

A Strategic Approach to Localization

In recent years, KION has deepened its commitment to building and refining capability in South Carolina. A major initiative has centered on localizing key manufacturing processes that were historically completed abroad. By bringing critical operations under one roof in Summerville, the company has strengthened quality control, increased responsiveness, and expanded opportunities for employee development.

Daniel summarized the philosophy succinctly: “When you bring the work home, you gain speed, control, and the ability to train people directly. That’s where the real advantage lies.”

Plant 1 – Customization, Quality, and a Culture of Learning

The tour began in Plant 1, where KION builds to order – not for stock. Every truck that leaves the Summerville campus is built to a specific customer requirement, supported by disciplined planning and synchronized execution.

Members observed KION’s quality systems and daily SQDIP reviews, where issues are tracked, discussed, and addressed in real time. Digital tools play an increasing role, and Daniel welcomed dialogue around evolving technologies like digital work instructions and integrated inspection systems.

Training was a recurring theme throughout the visit. Before touching a wrench or tool, every new associate goes through focused onboarding in a dedicated training environment. “I’d rather someone discover this isn’t the right fit early than after weeks on the floor,” Daniel said. That investment has contributed to higher engagement and stronger retention.

KION’s operating philosophy was clear: flexibility powered by discipline, and automation guided by people.

Plant 4 – Smart Logistics, Purpose-Built Flow

The group then entered Plant 4, the company’s newly designed logistics hub. The facility was purpose-built for the scale and physical size of the material KION manages. Tall clear heights, specialized storage systems, and wire-guided equipment allow KION to move large components efficiently and safely.

Logistics engineer Gabe Godfroy – described by Daniel as “the master behind the setup” – supports a system designed for continuous flow. Cycle counting, traceability, and cross-functional collaboration are built into the daily rhythm, eliminating disruptions and improving accuracy. A designated “red zone” for supplier issues allows planning and procurement teams to solve problems quickly with direct visibility.

Here, logistics is more than warehousing – it’s a strategic function that protects flow.

Plant 3 – The Heart of “Home Turf”

Plant 3 showcases the core of KION’s localization strategy: mast fabrication. Watching raw steel transform into the structural backbone of a forklift brought KION’s craftsmanship into sharp focus.

Automation plays a significant role, but always with people at the center. Skilled technicians oversee six-axis CNC machining, robotic welding cells, and powder-coating systems. Among them is Joe Moore – known on the floor as “Robo Joe” – who transitioned from manual welding to programming and managing robotic systems after specialized training. His pride was evident: “When we finish welding,” he said, “everything fits like butter.”

The tour concluded in mast assembly, where precision, automation, and craftsmanship converge.

A Culture of Capability

KION’s Summerville campus reflects a unified strategy grounded in people, process, and technology. Whether in tailored assembly, smart logistics, or advanced fabrication, the company’s focus on training, discipline, and continuous improvement was evident at every step.

Daniel summarized the spirit behind it: “This isn’t just about building forklifts. It’s about building capability – right here at home. This is Home Turf.”

About KION Group

KION Group is a global leader in industrial trucks, warehouse technology, and supply chain solutions, providing innovative products and services that help businesses move goods efficiently and safely. Headquartered in Germany, KION combines advanced automation, digitalization, and human expertise to deliver solutions that are both flexible and reliable. Its portfolio includes a range of industrial trucks–from electric and internal combustion counterbalance trucks to automated guided vehicles (AGVs)–as well as comprehensive warehouse management systems and services. Guided by the philosophy of “Flexibility powered by discipline, automation guided by people,” KION is committed to helping companies optimize operations while prioritizing the safety and development of their workforce.
https://www.kiongroup.com/en/

About OpExChange

The OpExChange, a program of the South Carolina Manufacturing Extension Partnership (SCMEP), is the only peer-to-peer network of manufacturers and distributors across South Carolina. For over 23 years, this collaborative group has helped member companies improve performance through benchmarking, best practice sharing, and collective learning. Member companies regularly host site visits and events, offering real-world examples of industrial automation, lean manufacturing initiatives, workforce engagement, and leadership development. It is an invaluable resource for South Carolina manufacturers seeking to learn from others on similar operational excellence journeys.

If your company is interested in joining this collaborative effort to strengthen both your operation and South Carolina’s manufacturing community, reach out to Mike Demos at mdemos@scmep.org. Visit www.OpExChange.com for more information on joining and a list of upcoming plant visits.

Reference Section for OpExChange members

OpExChange Members – Access Videos and Pictures from the visit on the OpExChange Portal. This is open to OpExChange member sites. (If you cannot access the Portal, request login instructions from Mike Demos.)