AIH Group is an independent service provider for Contract Vehicle Assembly, MOD Centre services, Special Vehicle Conversions and Production Logistics solutions.
Vehicle Contract Assembly
Our focus
AIH Group is an independent contract assembler specialising in niche market vehicle assembly. As a registered contract assembler, we provide comprehensive assembly solutions for Original Equipment Manufacturers that lack in-house assembly capabilities. We have a fully equipped scalable facility with an inventory and production management system.
Service offering
We take full responsibility for delivering a fully equipped and operational assembly plant tailored to our clients’ specific needs, driven by key performance indicators related to process efficiency, volume targets, and quality standards.
AIH Group developed a unique platform called GateKeeper to manage and control the Inventory and Assembly processes all in a single platform, to provide users control over baseline procedures used in assembly operations and with stock control.
The AIH Semi Knock Down (SKD) Assembly Plant in Durban adheres to the QAS INTERNATIONAL (London-based verification and certification body) ISO 9001:2015 standards. Our commitment to quality encompasses documentary control and built-in quality processes.
AIH Group offers flexible location and facility options for contract assembly, ensuring that our services are tailored to meet the specific needs of our clients. We can accommodate assembly operations at a variety of locations, including:
Reference project
Mahindra Contract Assembly
Our SKD contract assembly plant, located in the Dube Free Trade Zone in Durban, South Africa, is an independent Contract Assembler for Mahindra South Africa. Mahindra first started producing single cab Pik Up models at the plant before increasing the plant’s capabilities and the complexity of its semi-knocked down line to reach a point where each Pik Up is a complete nuts and bolts assembly. The Mahindra Assembly Facility could rightfully be described as the largest and most complex of its kind on the African continent if one considers single-brand facilities that produce a consistent flow of vehicles every month.
MOD Centre Services
Our focus
Providing MOD Center services, we’re the go-to partner for car manufacturers who want to add excitement to their new-vehicle model ranges, whether it’s through a discreet engineering project or a total new-model enhancement program, from sketch to showroom. Our independent modification services are tailored for our OEM clients. Our involvement begins with project scoping, where we collaborate with customers to understand their needs. From there, we develop concepts and cost estimates that culminate in a comprehensive business plan.
Service offering
Our process encompasses product development and secondary assembly, which can take place either at AIH facilities, partner locations, or the OEM’s own facility.
The Pre-Project Scoping Study covers: Concept designs Bill of Materials (BOM) Supplier Engagement Business Case Development “Mule” Vehicle (de-risk)
The Product Development phase covers:
- Prototype development
- Product Design
- Aesthetic
- Finite Elemental Analyis (FEA)
- Design Failure Modes and Effects Analysis (DMFEA and Design Validation Plan (DVP)
- Physical Test and Development
- Supplier Management including tooling and component manufacturing
- Production Part Approval Process (PPAP)
- Homologation and Certification
- Sign Off
The Product Development phase covers Facility Specifications Facility Layout Facility setup Logistics Planning & Implementation
Product Development covers Intercept vehicle at OEMs Logistics processes Install/Replace/Remove/Add selected newly developed components and systems to create unique variant Supplier incoming goods quality management Inventory Management Final vehicle sign off Aftersales support (including Warranty Coverage for AIH-responsible parts)
Reference project
Nissan Navarra Warrior
This hardcore flagship conversion of the double-cab bakkie is now in pre-production by AIH Group subsidiary Premcar SA. This follows agreement between Nissan South Africa and Melbourne-based Premcar – the Australian automotive engineering firm that developed the Nissan-backed package – to offer the Warrior derivative in South Africa
Special Vehicle Conversions
Our focus
AIH Group is proud to offer specialised vehicle conversion services tailored to meet the unique needs of our clients. Whether it's a one-off project or a series of custom modifications to support market demands, we provide flexible options to ensure customer satisfaction. Our conversion process typically occurs on the production line, when applicable, or in a dedicated area adjacent to it. This setup allows us to seamlessly integrate modifications into our existing production workflow while maintaining high standards of quality.
Service offering
- Determine the specific requirements and purpose of the conversion
- Engage stakeholders to gather input and ensure all needs are met.
- Develop a detailed design plan that addresses the conversion goals, safety, and usability.
- Create sketches, renderings, or CAD models to visualise the conversion.
- Identify necessary modifications, including structural changes, layout, and equipment needs.
- Identify and procure the necessary materials, hardware, and components required for the conversion.
- Source suppliers for specialised equipment (e.g., lifts for mobility vehicles, firefighting equipment for emergency vehicles).
- Physical modification of the vehicle, which can include:
- Drivetrain upgrades or changes.
- Structural modifications (e.g., adding a raised roof, cutting out sections for equipment).
- Interior customisation (e.g., installing seating, storage, or specialized equipment).
- Ensure all modifications are securely fastened and safe for operation.
- Research and ensure compliance with local, state, and federal regulations, including safety standards, emissions requirements, and any special design approvals.
- Obtain necessary permits or certifications for the modification.
- Conduct thorough testing of the modified vehicle to ensure safety and performance.
- Address any issues or adjustments needed as a result of testing.
- Ensure all systems function correctly and meet regulatory standards.
- Perform a final inspection to confirm the vehicle meets design specifications and safety regulations.
- Obtain any required certifications and approvals from governing bodies.
- Offer ongoing support, maintenance, and service for the modified vehicle to enhance longevity and performance.
- Collect feedback for future conversions or improvements.
Reference project
Mahindra Karoo Editions
Our Dube plant also produces for Mahindra South Africa its double cab and special edition models, such as the very popular Karoo Editions. The range includes the Karoo Dawn, Karoo Dusk and Karoo Storm.
Reference project
Land Rover 147
AIH Group delivers special vehicle conversion solutions. We designed and developed the Land Rover Defender 147 as a 7-door. It can carry 13 passengers but comes with a variety of options. The Defender 147 has been used predominantly by safari and tour operators in South Africa. There are also 147s in use at Solihull in UK for Land Rover Factory tours.
Production Logistics
Our focus
AIH Group is an automotive production logistics service provider for value-adding supply to manufacturing operations. We deliver services to clients through a centralised consolidation centre or directly at their facilities. Our focus is to optimise the supply chain and enhance efficiency and reliability in delivering to OEMs and Tier 1 clients.
Service offering
We provide comprehensive sub-assembly services tailored for OEMs and tier 1-3 suppliers. Following assembly, we supply modules directly from our center to the OEM production line, utilising a batch or Just-In-Time (JIT) approach. This ensures that components are delivered precisely when needed, minimising downtime and maximising productivity.
Understanding the demands of high-volume production, AIH is committed to delivering components Just-In-Time (JIT) and Just-In-Sequence (JIS). Our systems integrate seamlessly with suppliers and OEMs, leveraging advanced IT solutions to synchronise deliveries with production schedules, thereby optimising workflow and reducing inventory costs.
AIH operates a purpose-built stock management system that integrates with our OEM partners in a synchronized manner. This integration allows for real-time stock control and management, ensuring timely deliveries and accurate inventory levels, all contributing to a streamlined production process.
We maintain a fleet of dedicated transport vehicles, ensuring the safe and efficient delivery of goods to our clients. Our logistics team is trained to handle the complexities of automotive parts transport, guaranteeing that components arrive on time and in optimal condition.
Our logistics service extends to line-loading directly at the OEM assembly lines. This process ensures that components are delivered and organized efficiently, ready for immediate use in the production process, thereby enhancing assembly line productivity.
Reference project
AIH Logistics North Tshwane SEZ Plant
From our facility in the Tshwane Automotive SEZ, AIH Group subsidiary AIH Logistics North delivers Production Logistics solutions to the adjacent Ford plant building the new generation Ford Ranger. We provide sub-assembly, stock-holding, batch control and JIT/JIS supply and line-loading at the assembly line.
