Inside the WEG Factory: A first-hand look at global manufacturing excellence
In October last year, I had the opportunity to visit the WEG manufacturing facilities in Brazil, alongside the team from TR Industries and a group of valued customers. The visit offered a rare look behind the scenes of one of the world’s leading electric motor manufacturers.
After arriving in Brazil, the group travelled to Jaraguá do Sul, home to WEG’s global headquarters and primary manufacturing operations. From this point, we shifted our focus to understanding how WEG designs, manufactures, tests, and continuously improves its products at scale.
A global leader in electric motor manufacturing
The factory visit began with an overview of WEG’s global operations, setting the scene for the week ahead. The scale of the organisation is impressive, from the size of its manufacturing footprint to the breadth of its product range and the level of ongoing investment in research and development.
WEG’s headquarters alone spans more than one million square metres, producing tens of thousands of motors every day. A significant proportion of the company’s revenue comes from products developed within the past five years, highlighting a strong commitment to innovation and continuous improvement. Just as notable is WEG’s focus on sustainability, including extensive reforestation initiatives and high levels of recycled material used throughout manufacturing.
Manufacturing quality, from raw materials to final testing
One of the most valuable aspects of the visit was seeing the full manufacturing process first-hand. From copper wire production through to final motor testing, every stage demonstrated a high level of precision, automation, and quality control.
Observing enamel integrity testing, breakdown voltage standards, and final inspection processes provided strong reassurance that WEG’s testing parameters closely align with best-practice standards used here in New Zealand. The consistency and repeatability built into these processes reinforce the long-term reliability of the products.
Vertical integration in action
Throughout the week, WEG’s vertically integrated manufacturing model was clearly on display. Tooling, machinery, and many critical components are produced in-house, allowing greater control over quality, lead times, and innovation.
Visits to the tooling workshops and foundry highlighted how motor frames and components are manufactured, with up to 95% of casting material sourced from recycled internal offcuts. This approach not only improves efficiency but also supports WEG’s broader sustainability goals.
Advanced drives, motors, and automation
The tour also included panel manufacturing, medium-voltage drives, and motor and generator production. Some drive panels measured up to 10 metres in length, reflecting the scale and capability of the facility.
A particular highlight was seeing in-house coil manufacturing and stator winding in action. Watching experienced technicians rewind and assemble motors reinforced the level of skill required alongside advanced automation.
The controls and automation facilities further reinforced how robotics and smart logistics systems are used to move components efficiently throughout the plant. Automated vehicles, integrated workflows, and real-time coordination all contribute to an operation that is difficult to fully appreciate without seeing it first-hand.
Key Takeaways
Visiting the WEG factory provided valuable insight into what sits behind a globally trusted brand. The depth of engineering expertise, the investment in research and development, and the emphasis on quality and sustainability were evident at every stage of the tour.
Experiences like this strengthen confidence not just in the products themselves, but in the systems, people, and processes that support them. It was a highly informative visit and one that reinforced why WEG continues to be recognised as a leader in electric motor and drive technology worldwide.
Calvin Thackwray
Technical Manager
Summary:
This article documents a first-hand visit to the global manufacturing headquarters of WEG in Brazil, offering insight into how large-scale electric motors, drives, and automation systems are designed, manufactured, and tested. It explores WEG’s vertically integrated production model, quality control processes, advanced automation, and sustainability initiatives, including recycled materials and reforestation efforts. The visit highlights the engineering expertise, research and development focus, and manufacturing standards that support long-term reliability and performance, providing valuable context for customers and industry professionals seeking to understand what sits behind a globally trusted industrial brand.
