System partner for on-board electrical system and wiring harness production as well as test bench and automation systems, with own manufacturing in Neuching near Munich.
Kusalava International GmbH
Neuching (DE) · Houston (US) · Vijayawada (IN) · Telaprolu (IN) · Rudrapur (IN) · Visakhapatnam (IN)New on Amplifa
About Kusalava
Kusalava International GmbH is a system partner for on-board electrical system and wiring harness production as well as test bench and automation systems. At its European headquarters in Neuching near Munich, the company combines engineering, project coordination and its own manufacturing: prototypes, one-off pieces and small series of electrical wiring harnesses are produced on site. For high-volume series, the GmbH draws on the manufacturing capacities of its parent company Kusalava International Ltd. in India, which casts, machines and assembles cylinder liners in four plants. The services include wiring harness development according to KBL, VEC and KOBL, assembly and fitting, electrical wiring harness test systems (EOL) with continuity, short-circuit and HV testing, HIL systems as well as PLC programming, robot integration and Industry 4.0 solutions. Customers come from automotive (OEM & Tier 1), agricultural and special machinery, defence, aerospace, industry and medical technology. A further location in Houston serves the North American market.
- Site
- Neuching
- Processes
- Wiring harness development (KBL, VEC, KOBL), Wiring harness/cable assembly & fitting (on-board electrical system & wiring harness production), Own manufacturing of prototypes, one-off pieces & small series (Munich), Cross-section diagram, bill of materials, production documentation, Electrical wiring harness test systems (EOL), Continuity, short-circuit & HV testing, Hardware-in-the-Loop (HIL) systems, Test software development & automated test sequences
- Materials
- Copper, Casting (cylinder liners), Plastic, Casting
- Certificates
- IATF 16949, ISO 14001, ISO 9001, LV 214 / LV 215, USCAR
- Founded
- 2026
- Employees
- 2000+
- Industries
- Automotive (OEM & Tier 1), Agricultural & special machinery, Defence, Aerospace, Industry / production & automation, Healthcare / medical technology
- 01
Wiring harness development (KBL, VEC, KOBL)
- 02
Cross-section diagram, bill of materials, production documentation
- 03
Prototype and small-series manufacturing (Neuching)
- 04
Assembly & fitting
- 05
High-volume production (India)
- 06
EOL testing (continuity, short circuit, HV)
- 07
Reporting & quality assurance
Materials & Processes
Copper
Conductor material for electrical wiring harnesses and on-board electrical systems.
Plastic
Insulation and assembly material for wiring harnesses.
Casting
Material for cylinder liners in the group's foundry.
Locations
Neuching
DEEuropean headquarters, engineering, project coordination & own manufacturing (prototypes, one-off pieces, small series)
- Lot size
- Prototype, one-off piece, small series
- Materials
- Copper, plastic
- Wiring harness assembly
- Electrical wiring harness test systems (EOL)
- Continuity, short-circuit & HV testing
Houston
USAmerican headquarters, engineering and sales support for North America (USCAR)
Vijayawada
INParent group & Asian headquarters, Unit I: foundry, machining, assembly
- Lot size
- High-volume series
- Materials
- Casting
- Foundry
- Machining
- Assembly
Telaprolu
INUnit II: casting and machining capacity for OE and aftermarket
- Lot size
- High-volume series
- Materials
- Casting
- Foundry
- Machining
Rudrapur
INUnit III: plant Northern India (since 2006)
- Lot size
- High-volume series
- Materials
- Casting
Visakhapatnam
INUnit IV: coastal plant (since 2007), ISO 14001 certified since 2009
- Lot size
- High-volume series
- Materials
- Casting
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Wiring harness development (KBL, VEC, KOBL)Engineering | – | – | – | – | Copper (wires) |
| Wiring harness/cable assembly & fitting (on-board electrical system & wiring harness production)Joining | – | – | – | One-off pieces/prototypes – High-volume series | Copper (wires), Plastic (insulation/assembly) |
| Own manufacturing of prototypes, one-off pieces & small series (Munich)Assembly | – | – | – | One-off piece – Small series | – |
| Cross-section diagram, bill of materials, production documentationEngineering | – | – | – | – | – |
| Electrical wiring harness test systems (EOL)Testing | – | – | – | – | – |
| Continuity, short-circuit & HV testingTesting | – | – | – | – | – |
| Hardware-in-the-Loop (HIL) systemsTesting | – | – | – | – | – |
| Test software development & automated test sequencesEngineering | – | – | – | – | – |
| PLC programming (Siemens, Beckhoff, Allen-Bradley)Engineering | – | – | – | – | – |
| Robot integration & programmingAssembly | – | – | – | – | – |
| SCADA, HMI and MES integration / Industry 4.0 & IIoT integrationEngineering | – | – | – | – | – |
| Production line engineeringEngineering | – | – | – | – | – |
| Assembly of test bench systems and special machinery (automation systems)Assembly | – | – | – | – | – |
| Foundry (manufacture of cylinder liners, four plants in India)Casting | – | – | – | High-volume series | Casting |
| Machining (Indian plants)Machining | – | – | – | High-volume series | Casting |
| High-volume production (Kusalava International Ltd., India)Assembly | – | – | – | Small series – High-volume series | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Foundry | Kusalava International Ltd. | – | – | – | Vijayawada, Unit I (61,000 m²) |
| Foundry and machining | Kusalava International Ltd. | – | – | – | Telaprolu, Unit II (14,470 m²) |
| Manufacturing plant Northern India | Kusalava International Ltd. | – | – | 2006 | Rudrapur, Unit III (14,000 m²) |
| Manufacturing plant coastal plant | Kusalava International Ltd. | – | – | 2007 | Visakhapatnam, Unit IV (29,138 m²) |
Additional services
Quality
The processes follow the quality standards of the automotive and aerospace industries (IATF 16949, LV 214/LV 215, USCAR, DO-160/DO-254). Testing is performed on electrical wiring harness test systems with continuity, short-circuit and HV testing up to HIL systems.
| Evidence | Neuching | Vijayawada |
|---|---|---|
| ISO 9001 | ||
| IATF 16949 | ||
| ISO 14001 | ||
| LV 214 / LV 215 | ||
| USCAR |
History
- 1964
Founding of the Kusalava Group in Vijayawada
- 1969
Entry into the automotive business (FIAT dealerships)
- 1974
Foundry established; four plants for the manufacture of cylinder liners
- 1996
Founding of Kusalava International Inc, USA
- 1998
Partnership with Hyundai, establishment of passenger car dealerships
- 2006
Commissioning of Unit III in Rudrapur (plant Northern India)
- 2007
Commissioning of Unit IV in Visakhapatnam (coastal plant)
- 2009
ISO 14001 certification of the Visakhapatnam coastal plant
- 2020
Quantum Energy Limited — manufacturing of electric two-wheelers
- 2025
New Wiring Harness Division of Kusalava International Limited
- 2026
Founding of Kusalava International GmbH in Munich