60 years of DAF production in Belgium

In order to meet the increasing demand for DAF trucks, the production facilities needed to be expanded in the mid-1960s. Although there was enough space at the Eindhoven site, labour availability was limited. DAF therefore chose the Belgian Kempen region, where – following the closure of mines and regional diamond-cutting-workshops – a large labour force was available. Along the A13 highway at Oevel, a 400,000 m² area was acquired. The purchase contract was signed the day before Christmas 1964. Construction of a 12,000 m² factory began almost immediately, and it became operational in the first half of 1966.

‘Made in Belgium’

Since 1966, DAF trucks have been for an important part ‘Made in Belgium’, as the first four cabs came off the production line on 5 May of that year. Production increased rapidly, as evidenced by the fact that already on 5 July, the 1,000^th cab was transported from Oevel to Eindhoven. On 26 August, DAF Vlaanderen proudly reported that it was already able to produce ‘any type of cab’. In the meantime, the new paint shop was already running at full speed. After two impressive Müller presses were relocated from Eindhoven to Belgium on 1 December – a job that took two months – the factory finally became genuinely ‘self-supporting’. Just a few months later, DAF already decided to expand the cab factory preparing for the introduction of a whole new generation of trucks with revolutionary tilting cab in 1968.

Axle production also transferred to Belgium

The high quality of the cabs built by DAF Vlaanderen was the reason why the fast-growing DAF company also moved the axle factory from Eindhoven to Westerlo in 1971. A new 13,000 m² factory was added to the existing production line, increasing the length of the façade along the motorway to an impressive 380 metres. The number of employees gradually rose towards 1,000.

In 1985, DAF Vlaanderen saw further massive investment. A completely new factory for painting cabs was realised, at that time the most environmentally friendly in Europe. The axle factory also witnessed significant innovation less than three years later, in order to guarantee highest quality and performance of the axles. Because these are developed and manufactured in-house, DAF axles are always tailored exactly to the individual vehicle type for maximum efficiency.

New Generation DAF trucks

Investments in DAF’s axle and cab factory have continued over the past decade. In fact, more than €650 million has been invested in Westerlo in the past 10 years, primarily to support the completely new generation of trucks introduced recently. These are the first trucks on the market, developed from scratch, that meet the latest European vehicle masses and dimensions regulations. The DAF XD, XF, XG and XG⁺ were named ‘International Truck of the Year 2022 and 2023’, setting new benchmarks in efficiency, safety, and driver comfort. The electric versions of the XD and XF earned the prestigious award for 2026 – and their axles and cabs are also produced in Westerlo.

Impressive investments

One of the most striking examples of recent investment is the opening of a new, state-of-the-art cab paint shop, nearly 150 metres long and capable of applying 3,000 different colours. Its ultramodern paint robots deliver the highest level of quality while minimising paint consumption. Environmental impact was a major focus in its development: advanced paint systems have achieved a 50% reduction in emissions. The latest technologies are used to purify the air leaving the paint booths.

A completely new cab factory was also built. In the ‘Body’ department, around 145 robots work in sequence to produce the body-in-white cabs fully automatically, after which they are completed to customer specification in the ‘Trimming’ department. Great attention has been paid to ergonomics and optimal working conditions: lots of light, minimal noise, and cabs that can be adjusted in height to make working on them easier are just a few examples.

In the axle factory, fully automated production lines have been introduced over the past decade to increase output, further improve quality, and further optimise working conditions. The axle paint shop was completely modernised, with advanced robots drastically reducing paint consumption and environmental impact.

‘Factory of the Future’

It is precisely this combination of continuous investment in technology and innovation, together with a strong focus on sustainability and ergonomic working environments, that led Agoria – the Belgian technology federation – to name DAF Vlaanderen ‘Factory of the Future’ in 2024.

Production based on customer orders

Just like all other DAF factories, DAF Vlaanderen produces axles and cabs ‘sequential’ in accordance with the ’just-in-time’ principle. This means that cabs and axles are delivered to the DAF assembly plant in Eindhoven and to Leyland Trucks in Great Britain at exactly the right moment and in the right sequence, based on customer orders. The PACCAR Production System assumes that there is always room for further improvement and that employees know better than anyone else how their jobs can be done even better, more intelligently and more efficiently.

In 2021, the 3 million^th axle produced in Westerlo came off the production line; this year, DAF Vlaanderen will manufacture its 1.5 million^th cab.

“Fantastic recognition”

“Sixty years of production in Belgium is a tribute to the generations of employees who have built DAF in Westerlo into what it is today: an ultramodern, future-focused production site. And, of course, it is also a fantastic recognition for our 2,000 employees and 1,000 suppliers, including around 400 in Belgium,” stated Jos Habets, member of the DAF Board of Management and responsible for Production. “Thanks to their dedication and commitment, we are able to build trucks that lead the industry in terms of reliability, comfort, and quality. With our ongoing investments in DAF Trucks Vlaanderen N.V., our Belgian factory has a bright future ahead.”