By Mike Demos, OpExChange Coordinator for the SCMEP

Lyman, SC – In the nearly 24-year history of the OpExChange, no plant tour has been larger than the recent visit to SEW-Eurodrive’s Lyman, South Carolina campus. More than one hundred guests from forty-seven organizations, representing 17 counties, gathered to experience one of the more advanced manufacturing operations in the Southeast.

SEW-Eurodrive, a fourth-generation, family-owned global leader in drive technology, welcomed the group to its SMART Assembly Factory and MAXOLUTION® Showroom – two striking, award-winning facilities that represent the company’s dual commitment to technological innovation and people-focused culture.

A Factory Designed for the Future

Completed just three years ago, SEW-Eurodrive’s Lyman assembly facility was purpose-built for Industry 4.0, combining cutting-edge automation, fully paperless processes, and real-time digital integration.

The plant assembles a vast range of build-to-order gear motors, leveraging innovations such as:

• Digital Twins at supervisor stations, providing live production metrics and predictive maintenance insights.
• 33 Autonomous Guided Vehicles – known internally as HEDs (Highly Efficient Drive Systems) – that move parts seamlessly between stations, charged on the fly via SEW’s own MOVITRANS® contactless system.
• Paperless Digital Assembly Process (DAP) work instructions, providing step-by-step visual guidance and torque specifications to each assembler.
• Single-piece flow in a high-mix, medium-volume environment—something few manufacturers achieve.

The AGV fleet is a standout in the plant’s technology mix. These omnidirectional vehicles not only deliver materials with pinpoint precision but also recharge inductively while in operation – no docking required – allowing them to run virtually around the clock. Each is equipped with 4D cameras that detect moving objects and adjust speed or stop to ensure safe interaction with people on the floor. When necessary, they give a short, polite beep before resuming their route, creating a seamless, human-friendly coexistence between automation and operators.

As one guest put it, “SEW-Eurodrive’s ability to achieve single-piece flow in a high-mix, medium-volume environment was the biggest plus for me.”

A Culture That Keeps People

While the technology is impressive, SEW-Eurodrive’s leadership made clear that their people are the real differentiator.

Vice President Rainer Blickle, who participated in the entire event, put it plainly:

“Our engineers are the masterminds behind our products, but it’s our people on the floor who ensure the quality and craftsmanship that goes into every unit that we ship daily throughout the world.”

The numbers bear this out. Among the 155 employees at the Lyman site, the average tenure on the assembly team is 8.5 years – with twelve employees exceeding 20 years and seven surpassing 30 years. This loyalty is bolstered by intentional workforce decisions, such as:

• Structuring shifts to avoid second shift, giving employees better work-life balance.
• Providing bright, open workspaces with natural light.
• Offering comfortable, modern amenities – from “quiet cubes” for small meetings to immaculate restrooms (noted by visitors as a sign of respect for employees).

The result is a team that is engaged, knowledgeable, and clearly proud of their work.

Learning, Sharing, Improving

The OpExChange visit was structured to maximize value for both guests and hosts. The day began with a presentation by Rainer Neufeld, Corporate Electronics Manager, covering SEW-Eurodrive’s history, global presence, and the technology behind the SMART Factory.

Guests then broke into small groups for guided tours, stopping at key stations – from automated motor presses and lubrication systems to electronics assembly and final testing. Along the way, they observed more than 100 SEW products in operation, including powered rollers used by companies like Amazon and UPS, as well as other integrated robotics and motion systems working seamlessly within the facility.

One of the most impressive stops was the automated fluid filling station near the end of the assembly process. Here, an AGV delivers an assembled motor, its RFID tag triggering SAP to send the exact specifications—oil type and quantity – from a selection of twelve possible oils. A robotic arm, guided by a vision system, then locates the fill port and dispenses the precise amount required. This combination of AGV delivery, RFID-driven data transfer, and robotic precision eliminates errors, speeds up production, and ensures every motor leaves the line to exacting standards.

Following the tours, participants engaged in a collaborative improvement session, offering feedback and exchanging best practices. In the true spirit of the OpExChange, guests not only took away ideas for their own operations but also left SEW-Eurodrive with suggestions for continuous improvement.

The day concluded in the MAXOLUTION® Showroom, a 22,500-square-foot, architecturally award-winning space designed to highlight SEW-Eurodrive’s automation solutions. Over refreshments, conversations continued –cementing connections and sparking new ideas.

A World-Class Model

Visitor feedback reflected unanimous admiration for the facility and its people:

• “Every part of the tour was world class – exterior, common spaces, offices, manufacturing floor, processes, showroom.”
• “Coolest technology I’ve seen on an OpExChange event.”
• “The noise reduction in the plant and cleanliness is outstanding. The pride they show in their company and workplace is inspiring.”
• “This was an exceptional opportunity to showcase what is possible in a factory.”

Many left with practical takeaways – from material handling strategies to digital integration models – that they plan to adapt in their own facilities.

More Than a Tour

This visit was more than a plant tour – it was an immersive look at how a company can blend state-of-the-art automation with a deeply human workplace culture.

SEW-Eurodrive’s Lyman operation stands as proof that technology and people are not opposing forces but powerful partners. When employees are valued and empowered, and technology is thoughtfully integrated, the result is not just operational excellence – it’s an environment where innovation thrives and loyalty endures.

For the OpExChange, this historic event underscored the value of sharing best practices face-to-face. For SEW-Eurodrive, it was an opportunity to inspire others while continuing their own journey of continuous improvement.

About SEW-Eurodrive

SEW-EURODRIVE is a world-wide leader in power transmission products and services. As one of the largest manufacturers of electric motors, gear units, gearmotors, electronics and matching automation technology, SEW-EURODRIVE has become the go-to name for drive performance and reliability. Since introducing the gearmotor in 1931, we have been bringing the best in drive technology to our customers around the globe. That commitment has led to a history of innovations –  the first variable speed gearmotor, early development of electronic drives, some of the first successful efforts to decentralize control, and the first motor with energy-efficient copper rotors. Expanding to the U.S. led to the opening of our assembly center in Troy, Ohio, in 1975. Within a few short years, SEW was operating four additional regional assembly centers across the U.S. – in Bridgeport, NJ; Dallas, TX; Hayward, CA, and Lyman, SC. Today, we provide expert application assistance and products from our five regional assembly centers, more than 60 technical sales offices, and a nationwide distributor network. Worldwide, SEW-EURODRIVE employs more than 22,000 people and has presence in 53 countries. In addition, we have 15 manufacturing production facilities and 79 Drive Technology Centers supporting customers with a global portfolio of power transmission products and services. This network of locations allows us to think globally but service locally.

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

Employees at OpExChange Company Sites have full access to the event recap, including videos, pictures, and documentation. If you are a member and need login instructions, contact Mike Demos: mdemos@scmep.org.