[Report] "Increasing Production of Popular Models"... A Visit to KG Mobility's Pyeongtaek Plant

Report on KG Mobility Pyeongtaek Plant on the 23rd
50 Billion KRW Investment... Completion of 2nd and 3rd Line Integration
Mixed Production of Rexton, Tivoli, and Torres Electric Vehicles
Flexible Production Adapted to Market Conditions
Preparing for Electric Pickup Truck and Hybrid Vehicle Production

On the 23rd, at the KG Mobility factory located in Pyeongtaek, Gyeonggi Province, various car bodies of different shapes hang on a massive mechanical hanger. The front vehicle is a Rexton pickup truck, followed by the electric sports utility vehicle (SUV) Torres EVX. When it is the electric vehicle's turn for assembly, a huge battery pack descends from the second floor. Mechanical devices adjust the battery to its precise position and lift the massive battery to fit it under the vehicle. This entire process is automated, and once the final touches are made by human hands, electricity flows into the battery, activating it.

Last year, KG Mobility completed an integration construction project that reduced the existing three production lines to two. They stopped operating Line 2, which originally produced the small SUV Tivoli, and consolidated production into Line 3, increasing the number of models that can be produced per line. They strengthened mixed-model production to flexibly change the production models according to market demand.

In particular, during this integration, the configuration was changed so that all lines could produce electric vehicles. The newly integrated Line 3 produces both the Rexton and the Torres EVX together. KG Mobility’s Pyeongtaek factory is the only place in Korea where frame-body SUVs and electric vehicles are produced on the same line.

A worker is assembling the electric sports utility vehicle (SUV) Torres EVX at the KG Mobility Pyeongtaek plant.
[Photo by KG Mobility]

KG Mobility has continued its reputation as the ‘SUV specialist’ by producing vehicles with frame-body structures. A frame body is a form where the engine and parts are mounted on an H-shaped steel frame, and the body is placed on top. Although the vehicle becomes heavier, off-road performance is enhanced. On the other hand, a monocoque body strengthens the body rigidity without a separate frame, making the body itself the structure. While the relative rigidity is lower, the vehicle becomes lighter, improving fuel efficiency.

Because the vehicle structures are different, there are many difficulties in mixed-model production of the Rexton (frame body) and the Torres EVX (monocoque electric vehicle) on the same production line. Adding electric vehicles into the mix increases the variables even more.

However, KG Mobility decided on mixed-model production for production flexibility and invested 50 billion won. They created an automated system capable of transporting both the body and deck (floor) together and established equipment that can automatically install high-voltage batteries for electric vehicles. Through this, the production capacity of the Pyeongtaek factory increased from 22 to 30 vehicles per hour.

Lee Jin-woo, head of the Production Innovation Team, said, "We can now adjust production according to market demand at any time," adding, "We are fully prepared to enable mixed-model production as long as the platform is the same, even when new models are introduced in the future."

A worker is assembling the underbody of the electric sports utility vehicle (SUV) Torres EVX at the KG Mobility Pyeongtaek plant.
[Photo by KG Mobility]

In fact, empty spaces were noticeable throughout Assembly Plant 3 during the visit that day. These spaces are reserved for production when new models are introduced. KG Mobility plans to produce the monocoque pickup truck electric vehicle, scheduled for release next year, on Line 3. They are also preparing to produce hybrid models equipped with BYD batteries.

Park Jang-ho, head of the Production Headquarters, said, "The hybrid lineup can be produced on the current production lines without major modifications," and added, "Going forward, we plan to release new products considering hybrid models for all vehicle types."