Volume 3/6 - 2011
. â‚Ź5
The food production
leader page 19
The builder of Polish power and a patron of culture page 56
Trend of contemporary beauty page 39
Engines of the Industry page 68
News
Trade Shows
Country profiles
Companies profiles
www.manufacturing-journal.net
PRELUDE | Dear Readers!
M
odern business management books put emphasis mainly on the dynamics of growth of the organization. They say that the company develops only when its competitive position continues to strengthen, and the company itself carries on actions oriented on continuous expansion in all fields. The main aim of the company is to achieve total recognition among Customers and to dominate the market as much as it is allowed by the local antitrust regulations. From the university dissertations, full of graphs, tables and econometric models, one can learn that in order to enter the path of rapid growth. The organization must properly invest its capital, make accurate decisions, build its value on many levels, not to focus only on the balance of profit and loss... Everything that I wrote above, is undoubtedly true. But the practice of business activity shows also those companies, which are crucial to the existence of the greatest global giants. I am thinking about expert organizations: highly specialized, the most trusted suppliers, jealously observed by competitors, organizations that gather professionals and enthusiasts, fascinated for years by their contribution to chain of values created for the Customer. Besides the above said elements, there are certain areas by which corporate excellence is facilitated in the modern business world. The Sitech Sp. z o.o. pays attention to all these areas in order to see their organization triumph. Please, see their success story on page 78. In order to achieve excellence, the companies should have basics positive values and attitudes. As a good example of such company can serve us the Rusagro Group one of the largest vertically integrated agricultural holding in Russia. Specializing in the production of sugar, meat, grains as well as fats and oil products, the company operates in the large fast growing sectors of food production industry. Today Rusagro is the second largest Russian producer of sugar and beet sugar. It is also Russia’s leading producer of sugar from beets and raw cane sugar. In 2010 the company attained the leading position in the market of import and processing of raw cane sugar. Read full story on page 19. There are only few drivers who know what engines their cars are fitted with. This knowledge is vital, however, and Isuzu Motors Poland’s (Ispol) success story will tell you why. This automotive subsidiary can hardly be outshined by any of its business partners. The facts speak for themselves. Launched by Mr Leszek Balcerowicz himself, the plant has turned out more than 2 million engines for the industry tycoons such as Opel/Vauxhall, Honda and Mercruiser. Full report on page 68. Enjoy the magazine!
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Manufacturing-Journal | 1 |
CONTENTS |
Editor Patryk T. Zborowski
Zhabinka Sugar Plant
Profile Writers Anna Tomaszewska Bartosz Sowiński Elena Rozhko Jacek Głowacki Kinga Nykiel Łukasz Światowiec Magdalena Kucypera Magdalena Urban
page 15
Stovit Group Art Director Wojciech Kosmowski
page 33
Project Managers Katarzyna Marciniec Katarzyna Olszowska Marta Kaciupska
Kronospan Szczecinek
Administration Wioletta Adamczyk
page 46
Długa Street 48/38 31-146 Cracow Poland e-mail: info@manufacturing-journal.net advertising: pz@manufacturing-journal.net phone number: 0048 12 4337117 fax number: 0048 12 4337116 web: www.z-media.pl www.manufacturing-journal.net
Inter-System page 53
Wezi-tec
© Manufacturing Journal 2011 No part of this publication may be reproduced in any form for any purpose, other than short sections for the purpose of review, without prior consent of the publisher.
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page 71
Contents
Index: Articles:
CONTENTS | 1 2 4 7 10
Prelude Contents News Trade Shows Country profile
11 15 19 24 29
To Be The First, To Be The Best! Tradition and innovation The food production leader Innovation and Quality From grain manufacture to finished product and its delivery to retail outlets Stovit Group - makes the World a sweeter and a healthier place 60 years of everlasting success Trend of contemporary beauty 100 years of experience and love to one’s work With respect for nature A black pearl among enterprises Expert in construction The builder of Polish power and a patron of culture Corporate and Responsible A leader for ninety years A global leader among glass manufacturers Engines of the Industry Better - faster - innovative Professionalism for the customer An expert among professionals
33 36 39 43 46 50 53 56 59 62 65 68 71 74 78
Contents
Fabryka Transformatorów w Żychlinie Sp. z o.o. Fluor S.A. GT Poland Sp. z o.o. Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. Inter-System Sp. z o.o. ISUZU MOTORS POLSKA Sp. z o.o. Kronospan Szczecinek Opal Sp.j. PBG S.A. RENI ETTORE S.p.A. Run Chłodnia we Włocławku Sp. z o.o. Rusagro Group of Companies Saint-Gobain Glass Polska Sp. z o.o. Sitech Sp. z o.o. Skidel Sugar Factory JSC STOVIT GROUP Sp. z o.o. Stoylenskaya Niva Agro-industrial company OOO Tsesna-Astyk Concern LLP Wezi-tec Sp. z o.o. Zhabinka Sugar Plant OJSC
62 59 74 39 53 68 46 50 56 43 36 19 65 78 11 33 24 29 71 15
Advertising: Emeres-Produkt Sp.j. Fabryka Przewodów Energetycznych S.A. Galvo S.A. Glob Trans Sp. z o.o. Jupiter 9 Keller&Bohacek GmbH&Co. KG Mercier Infa, SLU MIŚ Transport i Spedycja Sp. j. Orion Sp. z o.o. Salmatec GmbH Shebekinsky machine-building plant Sucres&Denrees syngenta Teplocom Trio Group Uni-Tech LTD Yılmaz Makina San. Ve Tic. Ltd. Şti.
75 64 75 41 21 13 17 41 47 13 27 13 20 21 25 31 20
Manufacturing-Journal | 3 |
NEWS |
BioGaia signs agreement with the Haldex supplies anti-lock braking largest pharmaceutical company in the system to leading Chinese Bus Philippines for its probiotic chewable Manufacturers tablets
BioGaia signed a distribution agreement with United Laboratories Incorporated, the largest pharmaceutical company in the Philippines, for its probiotic chewable tablets. The tablets will be sold under the BioGaia brand and the launch is planned to the first half of 2012. United Laboratories has 6000 employees, the majority in the Philippines, but the company also has business in another 10 Asian countries. The agreement only concerns the Philippines, but BioGaia already has an agreement with United Laboratories’ subsidiary in China. BioGaia’s Probiotic chewable tablets are sold in 44 countries, in 23 of these under the BioGaia brand. - We are happy to partner with a science based company like BioGaia, says José María Ochave, Senior Vice President at United Laboratories Incorporated. - The Philippines has a population of around 90 million people and a growing economy, which is why this market can be very interesting although the average level of income is comparatively low. United Laboratories has several sales forces that visit doctors, that is to say work in line with the successful business model that we use around the world, says Peter Rothschild, President at BioGaia. More info: www.biogaia.com
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Two of the leading Chinese Bus manufactures Suzhou Kinglong and Golden Dragon have chosen Haldex as the supplier of ABS (Anti-lock Braking System), TK+. Two of the leading Chinese Bus manufactures, Suzhou Kinglong and Golden Dragon, have chosen Haldex as the supplier of Anti-lock Braking System, TK+. Serial supply to both customers has already started. The Haldex TK+ is a cost effective and expandable system for ABS or ABS/ASR on trucks and busses, using the latest communication standards for both engine control and diagnostics and combining proven pneumatic technology with the latest in electronic circuit design. “We are very pleased that major OEMs in China have chosen Haldex as their supplier. This strengthens our position of brake control systems for truck and bus market in China, which is in line with Haldex previously communicated strategic focusing on growth in emerging market”, said Aichang Li, Senior Vice President, Head of China. “We aim to take full advantage of the expected market growth in the commercial vehicle industry in China and leverage Haldex established position which we intend to strengthen even further through our own local production,” says Jay C. Longbottom, President and CEO, Haldex AB. “The adaptation of higher quality technology will continue to drive Haldex expansion in China. Contracts like these are central to our growth strategy.” Haldex in China has production located in Suzhou, a broad sales network and the head office situated in Shanghai. More info: www.haldex.com
Metso’s new technology center will be opened on September 22, 2011 in Vantaa, Finland
Strong demand in valves globally The opening ceremony of Metso’s new technology center takes place today in Vantaa. The fastest growing markets of the facility, which is specialized in manufacturing of engineered industrial valves, are the Middle East and China. The investment decision to build a new facility in Finland is a continuation of Metso’s strategy to strengthen valve services globally. The new center employs about 800 automation professionals. Production works in two shifts at record pace. “Our current deliveries have increased by half compared with the corresponding period in the previous year. Production is more than 2,500 valves per month, and volumes will be further increased in order to meet the growing global demand,” says Markku Simula, President of Flow Control business in Metso’s Automation business line. “We supply valves globally to major oil and gas companies like ExxonMobile and Petrobras, and global forestry and paper companies like Stora Enso. Especially companies in the Middle East, Brazil and China have recently invested at an accelerating pace in new production facilities,” explains Simula. Strengthening global network The investment made in Finland continues Metso’s strategy to strengthen valve operations globally. In 2010, Metso opened a new technology center in Shanghai, and the company is currently
Imtech to expand its ICT activities in south-east Asia
expanding its valve production facilities in the US. Metso also has high-class industrial valve facilities in Brazil and Germany. “We are continuously improving our services for the oil, gas and process industry as well as for the pulp and paper industry. Our customers’ processes are getting more demanding, and therefore our customers are constantly expecting better solutions and services from us. Now enabled by our new production facility, we have even better possibilities to boost production and develop quality and delivery performance with these high-technology products,” says Simula. The new technology center replaces the old production facilities located in many separate buildings in Roihupelto, Helsinki. The new facility further improves the possibilities for product development. Investing in product development has made Metso one of the leading suppliers of intelligent on-off and emergency shutdown (ESD) valves and applications for real-time condition monitoring. Metso focuses on services Metso’s strong position with the most demanding valve applications and realtime condition monitoring has made the company also a technology service provider. A good example is the service agreement covering 11 refineries, which Metso and Brazilian oil company Petrobras signed in spring 2011. More info: www.metso.com
Gouda - Imtech (technical services provider in Europe) is increasing its 50% interest in its ICT subsidiary F&M Asia to 100%, giving it total control over its growing ICT activities in south-east Asia. The deal will entail the acquisition by Imtech of the remaining shares currently held by its partner, ALK Holdings & Management. The acquisition will be paid for in cash and will contribute directly to the earnings per share. Following the acquisition, Imtech will achieve revenue of around 20 million euro per year in the south-east Asian ICT market, where it employs more than 70 employees. René van der Bruggen, CEO Imtech: ‘In the context of its 2015 growth strategy, Imtech sees good opportunities for international growth outside Europe in certain ICT niche markets, such as software solutions in emerging markets. In southeast Asia, we already had a 50% interest in F&M Asia, a subsidiary of our German ICT company Fritz & Macziol (FuM). Acquiring full control of this ICT company will enable us to push full steam ahead as we seek to secure further growth in our international ICT activities in the Philippines and Singapore in particular, where the ICT market is experiencing rapid growth. Further geographical expansion of our activities in this region will not be ruled out. The aim is to gain a strong ICT position in this part of the world.’ Imtech ICT in south-east Asia: strong growth ahead The Philippines, with a population of around 100 million, and Singapore, which is home to some 6 million people, are among the emerging markets of south-east Asia. The level of industrial production here is high, with an annual double digit growth nearly each year, which is reflected in a significant growth in ICT investments. In the Philippines alone, the volume on the ICT market rose in 2010 by 20% to 11 billion euro. There is a demand for state-of-theart ICT service providers with sufficient financial resources, ICT know-how and
reliable ICT services oriented towards the long term. F&M Asia, with branches in Manila and Singapore, was founded in 2006 by the current management, since when it has grown by at least 30% every year. The entire management will be staying on after the remaining share purchase, which will provide a strong basis for continuity. The business functions primarily as a major partner for IBM, who has declared it as its System Integration and Performance Partner in the region. F&M Asia specialises in IT infrastructure (especially Cloud Computing, where shared and configurable networks, applications, servers, data storage and additional IT services are offered to customers; and Virtualisation, the optimisation of the IT infrastructure), specific software solutions (including Business Analytics, ERP and Security) and IT services (such as Outsourcing and Managed Services). Part of the revenue is generated on the basis of off-shoring, where IT services are offered to Imtech’s European customers remotely. Working closely in partnership with IBM and supported by the European Imtech ICT headquarters, F&M Asia is expected to grow in its new capacity as a full Imtech ICT subsidiary. This entails maintaining its current growth track-record of at least 30% on average every year. At the same time, investigations are underway to see if further growth could be achieved by opening branches in nearby countries or territories like Hong Kong, Malaysia, Vietnam, Indonesia or Thailand, for example. The aim is to establish a strong ICT position in this part of the world. Imtech ICT already enjoys strong market positions in various parts of Europe, especially in the Netherlands, Belgium, Germany, Switzerland, Austria and the UK, and is making inroads in France and Romania. More info: www.imtech.eu
Manufacturing-Journal | 5 |
NEWS | European auto makers pave way for uniform system of e-vehicle charging The European automobile manufacturers have defined a comprehensive set of recommendations to standardise the charging of electrically-chargeable vehicles. The joint industry proposal will enable the use of one type of plug independent of car make, electricity provider or country. “This is a major step towards the broader introduction of electrically-chargeable vehicles in Europe and paves the way for a harmonised solution around the globe”, said Ivan Hodac, Secretary General of ACEA, the automobile manufacturers’ trade association. “We call on the European Commission, the standardisation bodies and the infrastructure providers to adopt these recommendations and to clear remaining issues as soon as possible.” Standardisation of the connection between the electricity grid and electrically-chargeable vehicles is one of the prerequisites to help e-mobility gain a viable market share. At present, a variety of solutions is used, leading to a fragmentation of the market across Europe and abroad. The industry recommendations cover the whole link between the public charging infrastructure and the vehicle inlet including the communication between the two, and they address both slow and fast charging with
direct or alternate current. As soon as approved by the relevant standardisation bodies, vehicle manufacturers will start integrating the uniform application in their production cycles. The auto industry advocates the full implementation for new vehicles types from 2017. A unique standard for vehicle charging will benefit all parties involved: the auto industry, the consumer and the infrastructure provider. “Standardisation provides predictability to investors; it enables economy of scale and reduces costs. We have also ensured a solution that meets the highest safety standards and is easy to use”, said Hodac. Most stakeholders assume a realistic market share for electrically-chargeable vehicles in the range of 3 to 10% of new sales by 2020 to 2025, depending on how quickly the most immediate challenges can be addressed. More info: www.acea..be
Outotec to deliver ferrochrome plant in China
Outotec has agreed with Mintal Group Co. Ltd., a large manufacturer of ferrochrome and stainless steel, on the design and delivery of a new ferrochrome plant to Baotou, in the Inner Mongolia, China. The contract value is not disclosed but deliveries with similar delivery scope are typically worth of some tens of millions of Euros. Outotec’s scope of delivery includes engineering and supply of proprietary and other key equipment and an operating licence for the proprietary technology for a Steel Belt Sintering plant with annual capacity of 700,000 tonnes of chromite pellets and two 69 MVA smelting furnaces with preheating technology. The new plant will produce annually 300,000 tonnes of ferrochrome and it is estimated to become operational in 2013. “Ferrochrome production for the stainless steel industry and the demand of sustainable technology are increasing in China. We have recently seen a clear tightening of environmental regulations there. Outotec® Ferrochrome Process is a benchmark in terms of energy efficiency and widely used in major ferrochrome producing countries, such as South Africa and Kazakhstan. This is our first delivery of this technology to China and we see great opportunities for further deliveries to help our Chinese customers to meet the future environmental regulations”, says Outotec CEO Pertti Korhonen. More info: www.outotec.com
| 6 | Manufacturing-Journal
Neste Oil starts up Europe’s largest renewable diesel plant in Rotterdam
TRADE SHOWS
More info: www.nesteoil.com
Neste Oil has successfully started up Europe’s largest renewable diesel plant in Rotterdam in the Netherlands. Production of NExBTL renewable diesel at the new plant will be ramped up on a phased basis. The start-up is a significant milestone in Neste Oil’s cleaner traffic strategy and consolidates the company’s position as the world’s leading producer of renewable diesel. The plant was completed on-schedule and on-budget. “We are very proud of the new plant in Rotterdam,” says Neste Oil’s President and CEO, Matti Lievonen. “It will help us meet demand in the European market, the world’s largest for renewable diesel.” The Rotterdam plant has a capacity of 800,000 t/a and will increase Neste Oil’s total renewable diesel capacity to 2 million t/a. Utilizing Neste Oil’s proprietary NExBTL technology, the plant can make flexible use of almost any vegetable oil or waste fat in the production of premium-quality renewable diesel. The plant employs approximately 150 people, consisting of 110 Neste Oil employees and 40 service provider personnel. Neste Oil already operates a renewable diesel plant in Singapore that came on
01.10 - 30.10 2011
SASO 2011 Construction, wood and metal industry, tool and equipment, energy, electrical engineering
stream in 2010 and two plants in Porvoo in Finland that came on stream in 2007 and 2009. All of Neste Oil’s NExBTL plants produce renewable diesel and have the capability to produce NExBTL renewable aviation fuel. “The Rotterdam plant is Neste Oil’s fourth facility producing high-quality renewable diesel. With its start-up, our major EUR 1.5 billion investment program aimed at increasing our renewable diesel production capacity has entered its final stage. The successful completion of the program underlines our strong commitment to providing solutions that help meet the world’s growing energy demand and need to reduce traffic-related emissions,” continues Lievonen. Neste Oil’s NExBTL renewable diesel is a premium fuel that is compatible with all diesel engines and existing fuel distribution systems. It offers excellent performance at low temperatures and can be used either blended with fossil diesel or as such. NExBTL helps reduce greenhouse gas emissions by 40-80% compared to fossil diesel. Its lower tailpipe emissions also make a valuable contribution to enhancing overall air quality, especially in urban areas.
01.10 - 30.10 2011
MASHEX 2011 International specialized Exhibition for Mechanical Engineering.
Venue: SAJAM d.o.o. Zoraniceva 61A/HR 21210 Solin Croatia www.sasofair.com
Venue: Crocus-Expo IEC Krasnogorsk 65-66 km Moscow Ring Road Russia www.mashex.ru
17.10 - 19.10 2011
21.10 - 23.10 2011
RAC 2011 Refrigeration and Air Conditioning Exhibition Venue: National Exhibition Centre Birmingham B40 1NT UK - United Kingdom www.racexhibition.com
KLIMAHOUSE UMBRIA 2011 International Trade Fair for Energy Efficient Construction Venue: Umbriafiere Piazza Mocada 06083 Bastia Umbra (Pg) Italy www.fierabolzano.it/klimahouseumbria
Manufacturing-Journal | 7 |
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COUNTRY PROFILE | Slovenia Full name: Republic of Slovenia Population: 2 million (UN, 2010) Capital: Ljubljana Area: 20,273 sq km (7,827 sq miles) Major language: Slovene Major religion: Christianity Life expectancy: 75 years (men), 83 years (women) (UN) Monetary unit: Euro Main exports: Machinery and transport equipment, chemicals, household goods GNI per capita: US $23,520 (World Bank, 2009) Internet domain: .si International dialling code: +386
A country with spectacular mountains, thick forests and a short Adriatic coastline, Slovenia also enjoys substantial economic and political stability. It was the only one of the former Yugoslav republics to be in the first wave of candidates for membership of the European Union. It joined in May 2004. Just a couple of months before EU entry, Slovenia became a member of Nato.
Overview
Unlike Croatia or Bosnia-Hercegovina, Slovenia’s independence from Yugoslavia was relatively bloodless. The move was undoubtedly aided by Western European recognition of the Slovenes’ aspirations and the low proportion of other ethnic groups in the country. Slovenia has always been the most prospePiran, a city in southwestern Slovenia on the Gulf of Piran
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rous region of the former Yugoslavia and has found the transition from a socialist economy to the capitalist free market easier than most. On 1 January 2007, it became the first of the new EU member states to join the eurozone. A year later, it became the first former communist state to take on the EU presidency. Politically, Slovenia was the most liberal republic within Yugoslavia. Throughout the 1980s there was pressure from Slovenia for greater political freedom and pluralism in the federation. This reputation was tarnished after independence when thousands of nationals of other former Yugoslav republics were removed from population records and lost residency rights. Parliament later passed a bill restoring their citizenship but a referendum held shortly before EU entry in
2004 overturned it by an overwhelming margin. Human rights groups expressed dismay at the move which embarrassed the leadership as it prepared to celebrate EU membership. Slovenia’s relations with Croatia have long been strained on account of a rumbling dispute over sea and land borders dating back to the break-up of Yugoslavia. Ljubljana dropped its opposition to Zagreb’s entry into NATO in March 2009, but continued to block Croatia’s EU membership bid for a further eight months, only agreeing to lift the embargo after a deal had been signed on the Piran border dispute in November 2009. The centre-right opposition demanded a referendum on the border deal, which the public narrowly approved in a June 2010 plebiscite.
ARTICLES |
Agriculture IndustrySkidel Sugar Factory
To Be The First, To Be The Best!
M
any of the plants that are common in Eastern Europe today are in fact relatively new for this region. It is the case with the sugar beets which appeared on the territory a little more than a century ago. Thanks to the favorable climate beet roots have been successfully cultivated and used for production of sugar. JSC Skidel Sugar Factory is a one of the leading Belarusian enterprises that processes sugar beets to produce sugar.
Significant Milestones
Established in 1946 in a small provincial town in the Grodno province, Skidel Sugar Factory became the first sugar production enterprise on the territory of the Republic of Belarus. In 1951 the plant has been put into operation and started building its processing and production capacity. Within the first three years the processing capacity of the enterprise reached 800 tons per day. In 1961 the new processing technologies were introduced which made processing of raw sugar canes and production of citric acid possible. The collapse of the Soviet Union in 1991 along with numerous changes in the economy without doubt had a negative effect on many industrial enterprises. However, Skidel Sugar Factory not only survived those difficult times, but managed to boost its capacity of processing sugar beets and as a result increased the production capacity. In 1997 the enterprise had been reorganized into an Joint Stock Company. In 1998 a bulk storage with capacity of 15 thousand tons had been put into operation. At the beginning of the new millennium, the processing capacity of sugar beets reached 4000 tons per day and the number of the employees at the plant increased to almost 1000 people. In 2003, the company management decided to start the reconstruction of the plant in order to double the production capacity.
More than just sugar
The enterprise combines workshops for production of sugar and citric acid, a storage space for up to 17 thousand tons of raw beets, and a storage space for the ready products. In addition to regular sugar, which is packed, in 50 kilo bags, and in 1 kilo paper bags of at the company produces extruded sugar.
Except for sugar, JSC Skidel Sugar Factory also manufactures other products that are related to production of sugar. Other main by-products of sugar production industry are molasses and beet pulp. Molasses is the most valuable raw material used for production of citric acid, ethyl alcohol, glycerol, acetone, as well as lactic, butyric, oxalic, acetic, and other acids. The company is the only producer of citric acid in the Republic of Belarus. Beet pulp, another by-product of sugar production, is used in production of fodder. Beet pulp contains easily digestible substances, and has a high nutrition value comparable to those of oats and hay. Therefore, beet pulp is a product highly demanded on the
FACT BOX
FULL NAME: JSC Skidel Sugar Factory PRESIDENT: Dmitry Egorov OPERATIONS: Agriculture ESTABLISHED: 1951 EMPLOYEES: 1000
www.ssf.by Manufacturing-Journal | 11 |
global market. Drying and granulation of beet pulp significantly increases its storage time providing an opportunity to sell this product in Belarus as well as in other countries. The workshop for production of dry beet pulp is equipped with high tech machines made by the German company Buttner. The production capacity of this workshop reaches 200 tons per day. Thus, JSC Skidel Sugar Factory launched the workshop that allowed the company to increase the share of exported products and to promote its products on the global market. The management of the company is striving to increase the investment in the development, modernization and reconstruction of production facilities. In 2008 the total amount of such investments reached 16 billion rubles. In 2003 the company has developed a strategy for increasing the production of sugar from sugar beets. It has been implemented during the next three years. And as a result the production capacity of the enterprise has reached the stable level of 850 thousand tons per annum. Additionally, the company achieved expansion of the beet root cultivation areas up to 17 thousand hectares. Among other things, modern advanced agronomic technologies were introduced to maximize the effectiveness of the beet root cultivation processes. Sugar beet farming areas were provided with seeds of high-yield hybrid sugar beets, with highly effective chemical fertilizers, and high performance agricultural machinery. Consequently, the average yield
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of sugar beets was brought to 450-500 tons per hectare. In terms of supply of raw materials JSC Skidel Sugar Factory is situated in the most favorable region in comparison with the other sugar production companies of the country. The farms from which the enterprise obtains its raw materials are located in the Grodno region, that has the highest yield of sugar beets in the country guaranteeing the plant full supply in raw materials. This applies to the production of sugar from locally obtained raw material. Additionally, the plant processes raw materials purchased from the foreign traders.
Quality, leadership, partnership
The quality standards of sugar and citric acid produced by JSC Skidel Sugar Factory are in compliance with STB ISO 9001-2009 quality management standard. The quality standards of production of dry granulated pulp are in compliance with GPM + Certification System for Fodder Industry 2006. High quality standards became one of the major aspects that advanced JSC Skidel Sugar Factory to the leading position in the country. In addition, modernization of production and various investment projects not only help the enterprise to boost production capacity but also allow to bring the quality of products to the world class level. During the first half of this year JSC Skidel Sugar Factory managed to sell 40% of its products on domestic market, and 60% were exported. JSC Skidel Sugar Factory constantly
LITHSOLVENT
KEBOCOR
Inhibitors for the protection of metal materials against acids
Corrosion inhibitors for long time conservation of metal surfaces as well as for closed and semi-open cooling water systems
KEBO-DS Scale inhibitor in evaporation stations
KEBOSOL Activators for alkaline cleaning solutions
KEBOPLEX Scale control aids for cooling water and waste water systems as well as alcohol distilleries
Special Chemicals
KEBOCID Disinfectant for juice extraction and cooling water circuits
KEBOSPUM Antifoams for each range of temperature
KEBO-X Boiler feed water conditioning agent
KELLER & BOHACEK GMBH & CO. KG P.O. BOX 33 02 60 D-40435 DÜSSELDORF TELEPHONE: +49(0)211 / 96 53-0 TELEFAX: +49(0)211 / 65 52 02 E-Mail: info@kebo.de Internet: http://www.kebo.de
One of the world’s leading sugar trading companies. SUCDEN PARIS 20-22, rue de la ville l’evêque 75008 Paris, France. Tel: +33 1 53 30 12 34 Email: trade@sucden.fr SUCDEN RUSSIA 3, per. Orlikov Bat B, 107804 Moscow, Russia Tel: +7 495 796 96 39 Email: sugar@sucden.ru
SUCRES & DENREES
www.sucden.com
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Manufacturing-Journal | 13 |
maintains its position as a leading sugar producer in the country. Moreover, the company was able to enter the world market and to increase its production capacity and output volumes. However, the globalization trend in the world economy require the company to be even more proactive. Therefore, in 2010 the management of the enterprise in cooperation with other Belarusian producers of sugar established a Belarusian agricultural company in Kiev, Ukraine. This measure was requested by the Ukrainian manufacturers of sugar that found themselves in very unfavorable conditions since the Ukrainian suppliers started importing sugar from Belarus at the dumping prices. The formed company is the only official representative of Belarusian sugar producers on the Ukrainian market and it will supply sugar at the prices specified on the Ukrainian domestic market. JSC Skidel Sugar Factory supplies many Belarusian enterprises such as Belbakaleya, Sahtorg, Minbakaleyatorg, Kommunarka, Krasny Pishevik, the ABC company and many others. As for the foreign partnerships, the company cooperates with Coca Cola Almaty Bottlers Ltd., Bealrusian Sugar Company in Moscow, and Belarusian Sugar Company in Kyrgyzstan.
Corporate responsibility
The company stands out from its competitors not only on the basis of the high production capacity. JSC Skidel Sugar Factory is striving to create the best possible conditions for its employees.
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The company offers an extended social packet. The employees have access to a nice restaurant serving national and European dishes. The company’s cultural centre gathers more than 200 employees. Adults and young people attend a vocal group. There is an pool club. Additionally, the employees have access to numerous recreation facilities. The management encourages organization of corporate events which are beneficial for fostering good team spirit. Among other things, the company’s baseball team is the oldest team in the country.
Components of Success
JSC Skidel Sugar Factory is the pioneer of sugar production industry in Belarus. It managed to survive within difficult economic conditions becoming a symbol of leadership, modernization, and improvement. Of course, the companies, producing sugar will always have consumers, but only those who can offer products of exceptional quality, in combination with improved packaging solutions, and unconventional marketing strategies will be able to attract customers and become leaders of the industry. All of the above applies to JSC Skidel Sugar Factory. Being on the market for sixty years now the plant successfully combines experience with modern equipment and a young, creative team.  Written by Elena Rozhko
ARTICLES |
Agriculture IndustryZhabinka Sugar Plant
Tradition and innovation
Z
habinka Sugar Plant OJSC is one of the major sugar manufacturers in the Republic of Belarus. The company offer includes sugar enriched in vitamins and microelements.
An outline of the plant’s history
General Director Victor Mironov
FACT BOX
The company was established in 1959 in Zhabinka, Brest Region of Belarus, following a decree issued by the Belarussian government. The plant started to operate in December 1963, with the design capacity of 3000 tons of sugar beet per day. In 1965, processing of raw sugar cane begun. Between 1992 and 2000 the design capacity of the plant was increased up to 4500 tons of sugar beet per day. In 1994, the quality system ISO 9001:2001 has been introduced and certified. 2005 year was the period of implementing the packaging lines, producing 1 kg paper bags and 5 g stick packs. In 2007, new type of production has been introduced - “Gelling Sugar Classic”. In 2008, the design capacity of the plant has been increased again and
reached 7000 tons of sugar beet processed per day. In 2009, new production line has been introduced: “Granulated Dried Sugar Beet Pulp”. On 22 October 2010, the plant received a GMP certification on the Production of Fodder Substances. In the same year, bulk storage of sugar with the capacity of 50 thousand of tons, has been introduced. In the same year, products under the brand “SWEET LINE” have been released. In the following year, a new product has been introduced: “Sugar enriched in iodine, selenium, Vitamin E and folic acid.” In 2012 the company wants to put into operation a sugar packaging plant, which will broaden the range of packed sugar offered by the plant.
FULL NAME: Zhabinka Sugar Plant OJSC GENERAL DIRECTOR: Victor Mironov OPERATIONS: Agriculture Industry ESTABLISHED: 1959 EMPLOYEES: 800 people TURNOVER: 172 mln USD
www.sahar.by
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The company’s strategic potential
The main rule that the company follows is to release only products of high quality. This goal is directly connected with the production strategy, which is based on the continuous control of raw materials’ quality, active investments and implementation of the modern production technologies, as well as introduction of the most up-to-date quality technologies. The company owes its success to the high quality of production and its compliance with modern standards. The aforementioned strategy made possible for Zhabinka Sugar Plant OJSC to earn customers’ trust. Cooperation with partners, on the other hand, is built on the principle of mutual understanding as well as mutual respect for interests and values. The company underlines that it is ready to broaden its products’ range and to exceed the customers’ expectations. It also puts emphasis on the rules of ethical competition and advertising.
Production characteristics
Zhabinka Sugar Plant OJSC encourages the customers to look at ordinary product, sugar, from a completely new perspective. The company offers the following products: sugar (packed in bags weighing 5 grams, in cartoons of 120 pieces, in polypropylene bags weighing 50 kg, in paper bags weighing 1 kg or sugar sold by weight); beet pulp – a product used as fodder; beet molasses – after fermentation used for the production of the following products: during anaerobic process - ethyl alcohol, glycerin, butanol, acetone, butylene glycol, lactic, butyric, propionic and other acids, while during aerobic process - gluconic, citric, fumaric, oxalic and acetic acids as well as dihydroxyacetone; filter cake – a lyme fertilizer, application of which increases agricultural crop capacity, and lime - used in technological process of syrup refining, for disinfection of clamp field as well as stored beet. In 2010, as a part of the marketing development plan, a new brand “SWEET LINE”was developed. This is a modern brand, where the particular emphasis is put on health. It represents a new approach to sugar. Another flagship product of the company is “Gelling Sugar Classic”, which can be easily used while preparing jams and preserves at home, without food colourings and preservatives. Since 2011, simultaneously with white sugar production, the company initiated the release of
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sugar enriched in iodine, selenium, Vitamin E and folic acid. This sugar,enriched with vitamins and microelements, does not lose its characteristics during heat treatment. What is important, it makes meals not only sweet, but also healthy. What is more, there is continuous demand in animal husbandry for by-products received in the process of sugar production – beet molasses and sugar beet pulp. Planned reconstruction and constant modernization of production allows the company to use only the newest technological solutions. All the production released by the plant is made with the use of the modern, hightech equipment provided by the leading European manufacturers. The company selects its supliers using the following criteria: quality, price, payment procedure, as well as delivery conditions. Each potential supplier is thoroughly analysed, and history of deliveries is being checked before the cooperation is initiated. Among the suppliers who deliver sugar beet seeds, raw sugar, as well as raw and auxiliary materials to Zhabinka Sugar Plant OJSC, there are the following companies: KWS SAAT AG and Strube-Dieckmann GmbH and Co. Kg (Germany), Danisco Seed (Denmark), Wielkopolska Sugar Beet Breeding and
Seed Production Company (Poland), Cargill B.V. (the Netherlands), Sucreset Denrees (France) and Tate&Lyle (United Kingdom). The company’s suppliers are specialized agricultural enterprises, located in the following administrative districts of Belarus: Zhabinkovskiy, Baranovichskiy, Berezovskiy, Brestskiy, Drogichinskiy, Ivanovskiy, Ivachevitskiy, Kamenetskiy, Kobrinskiy, Lyakhovichskiy, Pinskiy, Pruzhanskiy and Stolinskiy.
Export destinations
Approximately 50 percent of produced sugar is exported to different destinations: from Poland, through Mongolia to Afghanistan. The company’s major clients are the Russian Federation and CIS countries, like for example: Kazakhstan, Kyrgyzstan and Ukraine. In the nearest future, the company plans to enter the European market.
Financial figures
Results for the financial year 2010 were satisfying. Net revenue was estimated at USD 177 million, which exceeded the result from 2009 of 53 percent. Level of profitability of released production exceeded 11 percent, while net profit was
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established at USD 10,3 million. Taking into account investment activity of the company in recent years, carried out as part of the programs to increase the productive capacity of the plant, Zhabinka Sugar Plant OJSC would like to keep the same high level of financial figures each year.
Human potential
Nowadays, the company employs more than 800 people. One of the priorities is to assure them decent working conditions, satisfying level of salaries, good working atmosphere, as well as proper health care and leisure conditions. A human beeing is in the centre of each investment programme or strategic plan undertaken by the company. The effectiveness of employees’ development, as well as development of social capital is recognized as a criterion of the continuous development of the plant as a whole.
The company’s mission and assumptions The company’s mission lies in the creation of high quality natural products, which can satisfy a high number of “sweet” needs of its customers. Active investments in the development of modern technologies and management are given high priority. The company adheres to the main pronciple, which is to release only high quality of production, as the quality guarantees reliability. Technical modernization of the production allowed the company to decrease expenses and increase the effectiveness of the plant as a whole.
in Russia, Ukraine, Kyrgyzstan, Georgia and Kazakhstan. The plant applies quality management system, as well as quality and safety management system designed for finished products and fodder production.
The company’s customers and partners
The company supplies sugar indirectly to the distributing facilities and to the enterprises from food industry for further processing. The company’s goal is to release safe production of high quality. Each client is equally important for the company, that is why customer orientation is one of the strategic assumptions of the company. Zhabinka Sugar Plant OJSC cooperates with the following enterprises operating in the sugar sector: Belarussian Sugar Company LLC (Moscow, Russia), Belarussian Agricultural Company LLC (Kiev, Ukraine), Belarussian Sugar Company LLC (Bishkek, Kyrgyzstan), Belarussian-Georgian Agricultural Company LLC (Tbilisi, Georgia) and Belarussian Agricultural Company LLP (Almaty, Kazakhstan). The company’s clientele comprises of
Major changes in the production
Today Zhabinka Sugar Plant OJSC is a major, high-tech and modern enterprise, which manufactures sugar and accompanying products, created during sugar production. In the last 5 years, export map of the company has been increased by several times. In the last 3 years, along with the other Belarussian sugar manufacturers, Zhabinka Sugar Plant OJSC created commercial chain
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both large distribution centres as well
as industrial processing companies, e.g.: Belbakaleya Plc, Belarussian Republican Union of Consumer Societies (Belcoopsoyuz), JV OJSC Spartak, OJSC Kommunarka, Slodych Confectionary Plant OJSC, OJSC Rogachevskiy Milk Cannery and OJSC Glubokskiy Molochnokonservny Combinat.
Perspectives for the nearest 5-10 years
In the nearest future the company plans to increase its design capacity up to 10 thousand tons of sugar beet per day, increase the range of production as well as further expand the market. The company is proud of the fact that for its regular customers “Belarussian Sugar” became a synonime of high standard quality, while the business with Zhabinka Sugar Plant OJSC – a synonime of an open, mutually benefiting and dynamic partnership. The company is aimed at maintaining this high level of the business reputation. The company hopes that European customers will soon become familiar and will have the opportunity to evaluate “SWEET LINE”products. Written by Magdalena Kucypera
ARTICLES |
Agriculture IndustryRusagro Group
The food production leader
R
usagro Group is one of the largest vertically integrated agricultural holding in Russia. Specializing in the production of sugar, meat, grains as well as fats and oil products, the company operates in the large fast growing sectors of food production industry. JSC Rusagro Group - the food production leader: Report based on an Exclusive Interview for Manufacturing Journal, with Maxim Basov - general director of Rusagro Group.
Development Timeline
General Director Maxim Basov
The shareholders of the company started working in the food industry already in 1995. At the beginning the company was supplying Russian confectionary companies with Ukrainian sugar, later on switching to import and processing of raw cane sugar. In order to guarantee the stability of sugar supply, between 1997-2003 the company acquired seven sugar production plants (2 of which were later sold) and some agricultural land suitable for cultivation of sugar beet plant. At the same time the company initiated the production of vegetable oil and fat based products in the Yekaterinburg, Krasnodar and Voronezh regions and launched its first retail brand - Chaykofsky. Since 2006, the company continued to grow and expand its central businesses, focusing
on the development of the sugar sector and the agricultural sector. Group of Companies Rusagro Ltd has been established in 2003, where members of the group owned all the company’s assets. In 2006 the company started to build a pig-breading farm in Belgorod, the construction of which had been completed in 2009. In the same year the company acquired two additional sugar production plants in the Belgorod and Tambov regions. In February 2010 the Group of Companies Rusagro Ltd had been reorganized into a joint stock company Rusagro Group holding 99% of company’s shares. In 2010 Rusagro started to build the second pig-breading farm in the Tambov region and increased its
FACT BOX
FULL NAME: Rusagro Group of Companies GENERAL DIRECTOR: Maxim Basov OPERATIONS: Food producer ESTABLISHED: 2003 EMPLOYEES: 11.500 people TURNOVER: 31 BN RUB
www.rusagrogroup.ru Manufacturing-Journal | 19 |
TEN YEARS
SYNGENTA
Sugar Beet Hybrids • • • • • •
High level of sugar content and easy processing Excellent field germination and early crop stand High percentage of monogerminity Complex disease resistance Easy harvesting and low mud content High yield potential
HM 1820, Nero, Silvetta, Kampai, Horta, Freja, Heracles, Atamansha, Prometa, Olympiada, Triada, Veles, Spartak, Silenta, Rasanta, Volga, Caligula, SY Oka, SY Rakolta
FORCE MAGNA
Best solution for early crop protection •
• •
Combination of two best insecticides – Thiametoxam (CRUISER) and Tefluthrin (FORCE) – which is used for sugar beet seeds pelleting Provides contact-systemic and gas-penetrating effect on soil and foliar pests Due to Vigor™ Effect it stimulates the development of root system and elevated parts of the plant which ensures stable and early shoots www.syngenta.ru
| 20 | Manufacturing-Journal
www.jupiter9.ru 500+
companies profiles available to read on our website
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land bank to 380 thousand hectares. In 2011 the company purchased 75% of shares of an oil production plant in the Samara region and started to design a pig-breeding complex in the Chelyabinsk region. Today Rusagro operates four major businesses successfully combining sugar, oil and meat production with the agricultural business.
The Efficiency the Sugar Business
Today Rusagro is the second largest Russian producer of sugar and beet sugar in Russia. It is also Russia’s leading producer of sugar from beets and raw cane sugar. In 2010 the company attained the leading position in the market of import and processing of raw cane sugar. The sugar business of Rusagro includes seven sugar production plants situated in the Belgorod and Tambov regions with a total production capacity of 3.784 tons of sugar beets and 1.043 tons of raw cane sugar. The company occupies the leading position on the market of pressed sugar, having 34% of the market share as reported by the retail audit company AC Nielsen (2010). The sugar business has a national distribution network. Successful development of the company can be attributed to its business strategy. The company constantly improves the efficiency of production
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by means of modernization and maintenance of sugar production plants. All sugar production factories are located in close proximity of each other and of the zones where sugar beet are cultivated. This gives the company significant advantages in terms of performance, allowing to move goods between the factories, to optimize the use of the existing resources, to minimize transportation and other logistics costs, and to control the supply of the sugar beets used for sugar production. The production capacity of all Rusagro’s sugar production plants allows year-round processing of raw cane sugar during periods when sugar beets are not available. In 2009, the company gained the leading position in the market for import and processing of raw cane sugar. In 2009, the company’s sugar production factories processed about 22% of all imported to Russia sugar, a total of 1.248 thousand tons. The production of sugar from raw cane sugar provides the opportunity to increase market share and ensure continuous supply of sugar throughout the year. Rusagro focuses on development of its brands: the companies trademarks Chaykofsky, Russian Sugar and Browni occupy a leading position in the sugar market. The product portfolio of the three sugar brands offers a selection of white and brown sugar, as well as
packed and pressed sugar. The volume of sugar production guarantees strong performance in all areas of business: sales, acquisitions and investments. Rusagro’s goal is to become the leading sugar producer in the CIS.
use and soil conservation. Alongside the introduction of modern technologies the specialists of Rusagro annually develop contingency plans for fertilizer usage for cultivated culture.
The Largest Agricultural Business in Russia
The Oil and Fats Business
The Rusagro Group is one of the largest and fastest-growing agricultural companies in Russia with a total land bank amounting to 400 thousand hectares, including 370 thousand hectares of arable land. The company produces sugar beets, barley, winter wheat, peas, sunflower seeds and soybeans. The agricultural business of the Rusagro Group includes two agricultural companies in the Belgorod and Tambov regions with
a total area of 400 thousand hectares. Additionally, the company has three grain elevators, with total capacity of 346.500 tons, which makes Rusagro one of the largest agricultural companies of the Russian Federation. The agricultural lands are located in the Belgorod, Tambov and Voronezh regions, which are known for their fertile soil that guarantee high crop yields annually. The lands are located in the near vicinity of the processing complexes, sugar and fodder plants and grain elevators. 100% of sugar beets are delivered to sugar production factories and grains are used for production of fodder for the pigbreeding farms owned by Rusagro. The company applies modern technologies for the cultivation of agricultural crops. The choice of brands of machines play an important role in the quality of field operations and ensures efficient energy
The Profitable Meat Business
The Rusagro Group is one of the top five manufacturers of margarine and mayonnaise in Russia. Additionally, the company is a leading supplier of packaged margarine to the markets of Central Asia. The production capacity of the fat plant owned by Rusagro guarantees the output of 63 tons of mayonnaise, 49 tons of margarine, 140 thousand tons vegetable oil, 2,000 tons of ketchup and other products. Rusagro occupies the fifth place in the Russian mayonnaise production market with a market share
The annual production capacity of the pig-breeding complexes owned by Rusagro is 62 thousand tons. The production efficiency is achieved through the use of the fodder base provided by the agricultural business and synergies with the grain business. At the moment the Belgorodsky Bacon company represents the meat business of the Rusagro Group on the Russian market. The Belgorodsky Bacon company has its manufacturing facilities in the Shebekinsky and Volokonovsky areas of the Belgorod region. With the annual capacity of meat production amounting to 62 thousand tons of pork in live weight, the company is among the five largest pork producers in Russia. As Rusagro’s goal is to become a leader in the meat market, the company has launched two major projects
of around 7% and is the leading producer of cooking margarine with a market share of over 30%. The main sales markets for the company’s oil and fat based products are the Eastern part of Russia - Urals Federal District and the adjacent areas of Siberia and the Volga region and Central Asia (Kazakhstan, Uzbekistan, Kyrgyzstan, Tajikistan), which in total amounts to the population about 80 million people. Rusagro is a leader in sales of mayonnaise in Russia as the company controls more than 30% of the market in its areas of distribution. Additionally, Rusagro is placed among the top three manufacturers of margarine in the abovementioned region. Today, the company’s goal is to become the largest producer of mayonnaise and margarine in the CIS.
in order to achieve its aim: the Tambov bacon project in the Zherdevskom and Sampurskom areas of the Tambov region and expanded its existed capacity in Belgorod by another 15 thousand tonnes. The predicted production capacity of the two plants will amount to 120 thousand tons in the Tambov region and more than 77 thousand tons in the Belgorod region. The pig farm of Belgorod Bacon operates in accordance with the world standards and uses the latest developments in science and technology for pig breeding and fodder production. The company operates in compliance with the environmental safety principles and carries out all the necessary control measurement at all operating locations in Shebekinsky and Volokonovsky areas. Written by Elena Rozhko
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ARTICLES |
Agriculture IndustryStoylenskaya Niva
Innovation and Quality
S
toylenskaya Niva AIC is one of the biggest agricultural holding companies in Russia. The company is a leading bread manufacturer on the Russian market. It occupies the third position among the chief flour producers, and the sixth position among the leading confectionary producers. The most important factor, due to which the company has gained this status is quality. “I think it’s an honor that we can actively participate in the economic development of Russia,” says the company’s president Drevlyansky Dmitriy.
Company profile
President Drevlyansky Dmitriy
FACT BOX
FULL NAME: OOO Agro-industrial company Stoylenskaya Niva OPERATIONS: manufacture of bakery and confectionery products, processing of grain PRODUCTION IN 2010: bakery products 184 thousand tons, confectionery - 25 thousand tons, flour - 344 thousand tons ESTABLISHED: 2000 (Stary Oskol, Belgorod region) EMPLOYEES: 10.000 people REVENUE: 9,4 billion rubles
www.stniva.ru
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At the moment, Stoylenskaya Niva incorporates 19 companies that are located in 8 regions of the Russian Federation. Total annual production capacity of the baking division is more than 320 thousand tons per year. The main emphasis is put on the production of confectionery products. This type of products is highly profitable, it generates the major part of total revenue of the company, but the output of baking enterprises of AIC Stoylenskaya Niva AIC is also very high. At present baking enterprises offer a choice of more than 300 products, of which 100 are different types of bread. The capacity of the grain processing division allows the company to store about 350 tons of grains and to recycle about 430 tons of grains per year.
Investment and achievement
Stoylenskaya Niva AIC was established in 2000. Today it is a diversified corporation that specializes in grain processing and manufacturing of baked goods and confectionary products. The company managed to maintain successful development during the world economic crisis. Strong financial position allowed to sustain operation of all technological and business processes, to avoid interruptions in the supply of raw materials and other resources, and to continue implementation of a technical refurbishment program. In 2008, the company was included on the list of 295 enterprises of strategic importance. The company has numerous plans for future development that include optimization of production and management processes, as well as building production capacity
through acquisition of new property. The corporation is interested in acquisition of the enterprises with stable production capacity of at least 25 tons per day. These investments are the priority for Stoylenskaya Niva AIC. It is also important to invest in the development of existing plants. The management of the holding company understands how important it is to optimize and develop the enterprises, to reduce production costs and improve product quality through technological renovation and introduction of new technologies. In 2009 Stoylenskaya Niva AIC invested 1 billion rubles in the purchase of new enterprises and 177 million was spent on renovation. In 2010 the investment in renovation reached 250 million. The company is planning to continue with its renovation program. Stoylenskaya Niva AIC strives to occupy the leading position in the cost formation process. This is achieved through introduction of new products, and through improvement of recipes, as well as through introduction of technological and industrial innovations and improvement the logistic practices. A continuous process of optimization of all operational aspects takes place at the company. The new system of retail sales has proven to be effective for the division of grain processing, now a similar systems is being developed for the baking division. In 2010, the company implemented a complex system of administration of all purchases that is being implemented at the enterprises that belong to the holding company. In December 2000, the company consisted of only two bakeries and one grain processing enterprise. Today Stoylenskaya
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Niva AIC is one of the largest holding companies of agriculture sector in Russia. For ten years, the annual revenue of the company has increased by more than a hundred and thirty five times, and the corporation has become on of the top three companies in the country in the production of baked goods and flour. By the end of 2010 Stoylenskaya Niva AIC managed to increase its net profit to 930 million rubles, or 83% compared with 507 million in 2009. In 2009 Stoylenskaya Niva AIC narrowed down its specialization by focusing on grain processing and bread production and sold the agricultural enterprises that it owned. By focusing its efforts on the development and implementation of strategies necessary for these particular activities, the company was able not only to concentrate on developing its central businesses, but also to significantly reduce costs. Today the company occupies the leading position in the market of flour and bread production. Another important indicator of a successful business is stability. It is important not only to achieve operational excellence, product and production quality but also to be able to sustain them. The main aim for the entire company is to be the best in the industry.
Quality Management
First, a certified quality management system that fully meets all international standards and requirements of ISO 9001:2000 is functioning at all of the plants that belong to Stoylenskaya Niva AIC. In addition, the quality management system has also been evaluated
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and certified by Russian specialized associations and organizations. All incoming raw materials are strictly controlled at all of the enterprises that belong to the holding company. The raw material are subject to quality checks and the documents are verified for compliance. Moreover, the company conducts checks for contamination, presence of pesticides, radionuclides, etc. Inspections are carried out in accordance with the industry requirements, and only on the basis of approved programs of technological control. In the process of production to baked goods all ingredients (syrup, sourdough, dough, etc.) as well as finished products undergo quality checks. Each year the high quality of products of Stoylenskaya Niva AIC is confirmed by the market experts and by ordinary consumers. The achievements of the company have been confirmed by many medals and diplomas. The company’s flour is a winner of many competitions, it received numerous medals for quality. Last year, the baked goods and confectionery products of Stoylenskaya Niva AIC won 7 medals at the international exhibition “Modern Baking 2010”. The list of the company’s accomplishments is very long, but the main conclusion is that Stoylenskaya Niva AIC maintains the highest standards of product quality. And today one the company’s
management has a very good understanding of how to effectively manage the enterprises and improve the quality of all processes.
Business development
The main strategic goal of Stoylenskaya Niva AIC is to preserve and strengthen its leading position on the Russian market of industrial processing of raw grain and food production. In other words to be the best at everything: quality, commerce, and finances. The main task of the management of the company is to increase asset prices both by introducing new technologies and by creating effective mechanisms of corporate governance and financial controls. It is very important that Stoylenskaya Niva AIC not only demonstrates a decent financial and operational results, but also is a leader in the professional activities, shaping the highest standards of quality in management and production.
Export Activity
In addition to Russian market, Stoylenskaya Niva AIC sells its products abroad. The company has signed contracts for the supply of flour and confectionery products to the U.S. and Germany. In the nearest future the company plans to establish cooperation chiefly with neighboring countries.
Employees
The company employs just under 10,000 people. Every member of the team is valued and respected. The company is interested in attracting young professionals. Therefore, it cooperated with the universities and provides young professionals with the opportunity to acquire practical skills. Written by Elena Rozhko main tasks is to sustain this high level of quality at all enterprises that are part of the corporation. The company’s management is aware that in modern conditions it is necessary to constantly improve quality in order to be effective on the market. This concerns not only quality of products but also the quality of asset management and business processes, the quality of corporate governance and financial controls. The company’s
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ARTICLES |
Agriculure IndustryTsesna-Astyk
From grain manufacture to finished product and its delivery to retail outlets
T
he history of the Concern dates back to 1969, when Tselinograd grain storage center was commissioned in the city of Tselinograd, Kazakh Soviet Socialist Republic (S.S.R.). None of the first managers of this enterprise could imagine how big changes the company will experience in the following 41 years.
Dates of the utmost importance to the history of the Concern
The decision to promote flour under the brand “Tsesna” was one of the most significant moments in the history of the Concern. At this point of time, the only flour manufactured in Kazakhstan was “impersonal”, no-brand flour. By virtue of a specific character of the product, development of a new, fully valuable brand was assessed by the majority of manufacturers as not promising. However, the Concern’s management held a different view, thanks to which the company became the first milling enterprise in the country, which initiated active promotion of the packaged flour on the market. As a result, today the trademark “Tsesna” is the most recognizable both in the territory of the Republic of Kazakhstan, and outside its boarders, in the countries to which Kazakh flour has been traditionally exported. Another step leading to increase of the effectiveness of the com-
pany’s operations was restructuring its sales strategy. Beginning in 1998, the company went through the process of a complex transformation. New distribution schemes, covering the whole territory of Kazakhstan, were developed, and logistic centers were opened in the big cities of the country. All these steps were aimed at decreasing the number of middlemen, introducing quality control system and efficient distribution of goods. In 2005, as a part of product line’s diversification, works on large-scale project to build a modern mill & pasta factory were initiated. The budget of this project increased KZT 2 billion (USD 15 million). Nowadays, this manufacturing complex reached full capacity, proving the rightness of the earlier taken decision.
Chairman of the board Nikolay Mesheryakov
FACT BOX
Today, the Concern consists of the following enterprises (subsidiaries and associates): FULL NAME: Concern Tsesna-Astyk LLP CHAIRMAN OF THE BOARD: Nikolay Mesheryakov OPERATIONS: Food production in grain processing industry ESTABLISHED: 1969 EMPLOYEES: 2500 people
www.tsesnaastyk.kz
Manufacturing-Journal | 29 |
•
• • • •
• •
companies involved in agricultural production: “Agro-Tses”LLP, “Khleborob” LLP and “Agrofirma Poisk” LLP; companies involved in the storage of agricultural production: “Elevator Tsesna-Astyk” LLP; companies involved in the production of flour: Mill Complex No.1, Mill Complex No. 2 and Koluton-95 LLP; companies involved in the production of pasta and macaroni products: “Tsesna-Mak” LLP; companies involved in the production of bread, bakery and confectionery products: “Tsesna-Astyk Bakery” LLP; companies involved in complete feed production: Complete Feed Mill; companies-distributors: “Astyk-Logistic” LLP and “Alma-Tses” LLP.
Substantial changes in the company’s operations during last 10 years Concern “Tsesna-Astyk” LLP is one of the leading enterprises within the grainprocessing industry of Kazakhstan. Taking into account its turnover, the Concern is one of the 100 largest companies operating in the Republic of Kazakhstan. Currently, the company employs over 2500 people. Today the company is a vertically integrated holding, creating closed loop supply chain - from grain manufacture to finished product and its delivery to retail outlets. Such structure allows reducing the company’s dependence on suppliers and allows to guarantee high, stable quality of manufactured goods. The companies associated with the Concern “Tsesna-Astyk” LLP operate in the following areas: • • •
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agricultural production with the total area of farmland estimated at 90 thousand hectares, storage of agricultural products with the total capacity of 170 thousand tons of grain, manufacture of products: produc-
•
tion capacity of the mill complexes processing soft wheat - 600 tons per day, production capacity of the mill complexes processing durum wheat – 100 tons per day, production capacity of the pasta factory – 48 tons of macaroni products per day, production capacity of the bakery – 67 tons of finished products per day, sale of products: own distribution companies located in the cities of the republican significance, namely Astana and Almaty and dealers network operating in 18 cities of Kazakhstan.
The company’s mission
The company’s aim is to manufacture high quality corn products, applying modern equipment and technology for its sale in Astana, in the whole Republic of Kazakhstan and abroad.
Production characteristics and range of products The total range of products released by the holding consists of more than 200 names (332 SKU – Stock Keeping Units), including: wheat flour (20 SKU), macaroni products (61 SKU), bread, bakery and confectionery products (210 SKU), groats (14 SKU), BAPOL (3 SKU, series “Healthy Products”), as well as rye flour, macaroni semolina and complete feed (20 SKU). What pertains to flour, the company offers the following types of this product: Elite Flour (made of selected grades of wheat), baking wheatflour: premium quality, baking wheatflour: first quality, baking wheat flour: second quality, as well as pancake flour, scone flour and festive flour for special occasions. Apart from “Tsesna” brand, the company also releases flour under another brand, “Salem”, at the lower price segment. The Concern is producing the following types of groats: barley and pearl groats, buckwheat groats, pea, millet groats, semolina and oatmeal. The company also offers macaroni products, all types of bread and bakery products, confectionery products, as well as complete feed (for pigs, laying hens, young birds and dairies). Apart from that, the Concern sells BAPOL, a natural food product with valuable physiological properties. Used every day, it effectively cleans the body form toxic substances and improves health. According to the
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Uni-Tech LTD Service and Engineering Company 7 years of presence in Kazakhstan, Uzbekistan, Kyrgyzstan, Turkmenistan, Azerbaijan, Armenia, Georgia and Europe. Highly skilled team of technical consultants and service engineers, 24/7 services support.
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- Line for production of short-cut pasta (penne, fuzilli) or special shapes 180 - 600 kg/h - Line of traditional lasagna 110/220/330 kg/h - Long pasta line for production of spaghetti (bucatini and nests) 220 - 450 kg/h - Multiline „Multipla” – short-cut pasta, spaghetti, lasagna and nests 320 - 600 kg/h - Automatic line of production 320 - 750 kg/h - Complete lines for production of ravioli and dumplings 150 - 400 kg/h - Horizontal and vertical packaging machines. Weight bags: 0,5 - 5 kg
050059, Almaty, The Republic of Kazakhstan Avenue Al-Farabi, 7, office 140, 6 floor Business Center „Nurly Tau”, Block 5A +7-727-2750222 (Multichannel) ext. 102 +7-727-3110026/27/28/29 (fax) +7-701-2040950/60/70/80 pastaprojects@uni-tech.asia
Manufacturing-Journal | 31 |
results of the marketing research “Tsesna” is currently the most recognizable brand among all existing on the Kazakh grain processing market. The brand continuously strengthens its position. What distinguishes the Concern from the other players of the grain processing market is departure from the stereotypes, susceptibility to innovation and high quality of offered products. Thanks to the aforementioned values, the company was able to make a real revolution on the flour market of Kazakhstan in 90’s. In various importing countries “Tsesna” flour become an embodiment of a better quality of the Kazakh flour.
quality products, proven in the market, the most modern equipment, the best production technologies and qualified personnel. In addition to the aforementioned, operating within the structures of a vertically integrated holding with well developed distribution channels gives the Concern the opportunity to bring high quality products indirectly to the customers. The company underlines that each customer is equally important to it and that the whole production process is focused on the end-customer.
Awards and certificates
Production technologies
Each structural unit of the holding is supplied with modern, high-tech equipment manufactured by the world leading producers from Switzerland, Germany, Italy and Poland: Uni-Tech, Buhler, Wachtel, Fawema, Ocrim and others. Milling equipment also comprises of the newest machinery: four-roller machines by Newtronic, purifiers by Puromat, plansifters by Novastar and others.
Export destinations
Currently, 40 percent of the Concern’s total production is successfully exported to Afghanistan, Tajikistan, Mongolia, Uzbekistan, Turkmenistan, Kyrgyzstan, Russia, Moldova, Belarus, South Korea and Georgia, whereas 60 percent of the production is distributed on the territory of Kazakhstan. The company consciously aims at keeping the ratio of 40x60 between export an domestic sales, which allows it to proceed with the most successful sales strategy, decrease its ex-
port dependency and hence, the possible risks the company may face. What pertains to the expansion into new markets, taking into account the most prospective ones, the company at first place considers Russia and China. Provided that effective logistic chain will be developed, export potential can be also seen in countries from South-Eastern Asia.
Strategic potential of the company
The key potential of the company is the opportunity to significantly increase its effectiveness by increasing sales volumes of finely packaged products with higher added value. The company’s production structure is being completely revised, taking into account the highest possible loading of its existing capacity. The Concern has everything that is necessary to achieve its goals: good
For several times the company was awarded, during regional and international trade fairs, gold medals for the high quality of manufactured products. The Concern has a title of “The Best Food Product on the Kazakh Market”, received during the republican competition “Altyn-Sapa”, supervised by the President of Kazakhstan. For its striving for leadership, advanced technology and innovation the company was awarded “International Quality Crown Award” Cup by international consulting organization “B.I.D.” The number of all awards achieved by the company includes 150 medals and diplomas. The company is proude of the personnel it employs within the structures of the Concern „Tsesna-Astyk” LLP. Those competent, indifferent and creative people are also the guarantee of the company’s success. The company assess positively the possibility of entering the European market in the nearest future and would like to encourage European customers to taste its products, asses their natural features as well as superb quality characteristics. The company is a member of the National Economic Chamber of Kazakhstan, the Union of Grain Processing Companies and Bakers from Kazakhstan, as well as the Grain Union of Kazakhstan. The Concern pursues the policy of openness, as part of which special trips are organized at the industrial premises of the company, to show the visitors how the production process looks like. During these trips, technologists working at the plant explain each stage of the process of transforming wheat into the finished product. Written by Magdalena Kucypera
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ARTICLES |
Food & Beverage IndustryStovit Group
Stovit Group - makes the World a sweeter and a healthier place FACT BOX
S
tovit Group is a manufacturer of jams, preserves and marmalades and for the past 15 years has been the runner-up on the Polish fruit processing market. In 2007, Stovit Group gained a strong partner – a Spanish enterprise called the Angel Camacho Group, one of the biggest olives manufacturers worldwide, which became the owner of the company. Cooperation with such a significant partner has changed the face of Stovit and brought in the exchange of experience regarding new technologies, the industry know-how and the development of Stovit’s product portfolio.
FULL NAME: STOVIT GROUP Sp. z o.o.
The beginnings of fruit processing in Bydgoszcz
PRESIDENT: Hanna Cendrowska
Stovit Group was founded in 1979 and originally it was meant to be a fruit and vegetable processing company. However, the fruit processing market turned out to be more attractive, hence the company adjusted its strategy and decided to focus on production of jam products. 1992 marks the date when the first jams from Stovit’s factory reached the Polish market. The emphasis put on jam products turned out to be extremely accurate, as quite soon the sales volume of jams and preserves doubled.
OPERATIONS: FMCG ESTABLISHED: 1979 EMPLOYEES: 145 TURNOVER: 49,7 mln PLN (2009)
www.stovit.com.pl
Rich portfolio of products
Currently, the range of products offered is quite impressive. Stovit offers jams, with both low and high sugar content, preserves, marmalades of various flavors, plum spreads, roasted apples, apple mousses, and meat and cheese accompaniments. Stovit is constantly working on new, innovative products that will meet customer’s demands and healthy trends on the market. These products are being distributed under various brands, including “Grandma’s Preserves”, “Premium” jams, “Premium” meat and cheese accompaniments and “Fruta” jams.
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Four lines of delicious jams...
When it comes to jams, Stovit Group offers its products in four well-known, different brands that vary in taste, price and size depending on the customers’ needs. Stovit Premium is a line designed for a demanding customer, which offers a great taste without any artificial additives. It’s a healthy and rich in ripe fruit jam that’s available in 7 different tastes. Apart from the exquisite taste and a jar of an interesting design, the jar’s lid is covered with famous Polish paintings, straight from the National Museum. Fruta Jams are meant for families as they are low sugar and available in small and large family capacities. Their earmarks are big pieces of fresh fruit dipped in tasty jam. Nine different flavors are available. GenuineFruit jams are high sugar jams offered for cuisine lovers. Finally, we have Mirella Jams, economy line of quality jams offered in 7 flavors.
Jams, marmalades, preserves, ...
But fruit processing is not all about the jams. Stovit Group’s offer goes far beyond that. Delicious, low sugar preserves are offered in 7 flavors based on a traditional recipe. As a Polish company, Stovit Group couldn’t do without plum confection, which is a traditional taste that one must try when visiting Poland. The company produces 3 different brands of plum spreads that will satisfy every cuisine lover. If one still fancies something sweet, there are many different flavors of marmalades, both soft and hard, produced at Stovit Group’s factory. These are also perfect for any pastries. Stovit’s portfolio also includes a line of products designed specifically for
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baking purposes – Fruta roasted apples and pitted cherries that allows anyone to quickly and easily prepare a pastry. Stovit’s offer is enriched with a variety of Premium cheese and meet accompaniments: cowberry, rowanberry, cranberry – designed to complete any meat or cheese dish. The company is also aware of its youngest customers. Specifically for them, one can find a gluten-free line of fruit mousses in 7 flavors and a childoriented, fairy tale packaging. The company’s product portfolio also includes a wide variety of items prepared for the foodservice sector. These include concentrated compotes, hotel jams, breakfast sets, jams and preserves in special packagings. Thanks to the wide range both of products and flavors, and to the high quality of the products, Stovit perfectly meets the taste of even the fussi-
est cuisine lovers. Products are delivered to retail and trade customers under Stovit’s brand and customers’ private labels, in Poland and worldwide.
How the best fruit makes the best jam
The high quality of the products is of great importance to Stovit. The production factory in Bydgoszcz was awarded with the BRC Global Food Standard Certificate, which combines the requirements of ISO 9000, HACCP, GMP and GHP. The production process in Bydgoszcz is being constantly monitored and controlled. Professional staff pays constant attention to the process and makes sure that any sources of potential risk are eliminated. The safety systems used at Stovit are being systematically verified by an independent certification company Lloyd’s Register Poland.
cacies - famous for its healthy properties and are recommended in nearly every diet. Stovit Group is aspiring to be more than just a producer and supplier for its customers. Recently, it launched a project called Culinary Academy where it recommends culinary solutions and shares special recipes that bring out the best taste of jams and marmalades. Stovit Group is putting a lot of emphasis on the quality of its customers lives, making them nicer and healthier; making them just a little bit more enjoyable. One bite at a time. Written by Łukasz Światowiec
Addressing the needs of clients
Clients and consumers are the source of valuable suggestions and ideas regarding the products but also regarding packaging, comfort and health. It’s reflected in the portfolio of Stovit. A wide variety of jams, preserves, marmalades and mousses, meets the price and taste demands of every gourmet eater. Products for specific consumer groups are also developed, such as children (a gluten-free fruit mousses) or the foodservice sector. There are also products focused on healthy living available. A series of dietetic jams sweetened with fructose is perfect for diabetics and overweight customers who cannot imagine one’s breakfast without delicious jam. The impressive portfolio of Stovit Group’s products is really a business lesson for anyone. Even being in such market as fruit processing, the company’s offer must address current issues and trends.
Making life a little sweeter and healthier
A glimpse at the portfolio really says it all about the company’s mission. It is to provide its customers with the top quality, natural and healthy products that satisfy the tastes of the choosiest eaters. The firm’s motto states: “Health and healthy diet account for serenity” and just one taste of Raspberry Premium Jam proves it right. It goes in line with recently introduced Bulerias products. Bulerias is a line of Spanish olives and Spanish deli-
Manufacturing-Journal | 35 |
ARTICLES |
Food & Beverage IndustryRUN Chłodnia
60 years of everlasting success
W
hen the global market for the sector is already heavily saturated, markets of individual countries hermetic and capricious, and competitive advantage due to the specific circumstances can not be achieved by using advanced technology, it would seem that it is very difficult for an effective expansion of companies from developing countries. Despite the difficult conditions of development, there are still organizations that successfully compete with industry giants. But to succeed, several conditions must be met, without which effective competition would not be possible. One of the organizations that has built its excellent brand, is RUN Chłodnia we Włocławku Ltd. Let us therefore analyze the activities of this rapidly growing company, to learn the secret of an efficient management of an organization in adverse market conditions.
Presentation of the company
During several decades of existence of the People’s Republic of Poland, its authorities were fiercely fighting all forms of private business initiative, and the word „capitalist” was used only in a pejorative context. Not surprisingly, the company founded in 1952 was state - owned, engaged in manufacturing frozen fruits, vegetables and ready meals. Unlike many other state - owned firms of that period, the company from Włocławek has grown dynamically and achieved many successes in the field of its activities. The result was the start of large scale exports of mainly cooked meat – vegetable products to the German market in the ‘80s. The company steadily expanded production and increased its assortment range, while purchasing invaluable experience in carrying out the needs of demanding Clients from Western Europe. Responsible development policy, drawing conclusions, and mastered to perfection ability to learn Western markets became first important factors, thanks to which the company achieved a great success in the future. In 1999, in the new socio – economic realities, the company found no difficulties in finding a strategic investor from abroad. The major stockholder of the company became RUN Polish - American Ltd. Founded in 1992, is famous for producing high quality sweet corn, primarily in the cobs. With such a strong investor RUN Chłodnia we Włocławku Ltd. obtained a powerful capital in the form of extensive know - how, and a number of excellent business contacts. These and other factors referred to below created the strenght of the brand and allowed a dynamic development of the organization. Nowadays RUN Chłodnia we Włocławku Ltd. is one of the European
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leaders in production of high quality frozen food and a provider of freezing and deep – freezing services. The company continually extends its product offer, responsibly matching its policy to the ever – changing requirements of the Customer. Except the two companies mentioned above, the RUN Group consists of Chłodnia Olsztyn and Rudopal in Opalenica.
The quality policy
In response to the current needs of Consumers, both manufacturing and service companies have to submit their whole activity to the Customer’s welfare. It is no
FACT BOX
FULL NAME: Run Chłodnia we Włocławku Sp. z o.o. PRESIDENT: Remigiusz Narkowicz OPERATIONS: Food & Beverage ESTABLISHED: 1952 EMPLOYEES: about 300 TURNOVER: about 12 823 399 Euro (2010)
www.runchlodnia.com.pl
different in the case of RUN Chłodnia we Włocławku Ltd. A coherent and consistently implemented project to maintain the highest quality of various products, is without a doubt the most significant, though not the only pillar of the success of the organization. The motto of the company, „better none than bad”, is just a starting point for a well - planned activity targeted at achieving a complete satisfaction of the Customer. In such a sensitive manufacturing area, which is the production of food, it is required the deepest commitment to the control and monitoring of the production process, in the area of occupational safety and health, and professional preparation of Employees to their tasks. Each of the 300 Employees working in RUN Chłodnia we Włocławku Ltd., together with the Chairman of the Board, Mr. Remigiusz Narkowicz, make every effort to ensure that the quality of the company’s products meet the strictest standards. To achieve this goal, the company operates in three complementary dimensions: firstly, it invests heavily in their Employees, by organizing a series of training courses covering issues related to occupational safety and health, as well as soft skills, such as more effective teamwork. The company has also developed an internal system of motivation, promoting appropriate effects of work of its Employees and their above-average abilities. Secondly, RUN Chłodnia we Włocławku Ltd. attaches great importance to technical resources, responsibly investing in the purchasing of modern manufacturing lines and equipment, and maintenance of the machines already owned. Reliability, flexibility and high performance devices provide, in addition to a very high quality products, the company’s
financial discipline through which, by the lowest possible production costs, the organization may offer its Customer the quality for a fair price. Thirdly, RUN Chłodnia we Włocławku Ltd. has obtained a number of certificates awarded at the highest levels by the most prestigious organizations in the world. The company boasts the BRC and IFS Certificates. International Food Standard Certificate, awarded to RUN Chłodnia we Włocławku Ltd. already in 2004 by TUV Nord - Cert at a higher level, ensures the implementation of the strictest standards of resource management, system for the allocation of responsibilities, quality management system and many other procedures. Annual recertification of the BRC standard at a very high A level, enables the organization to act freely on the English market, and certifies six vital business activities, including the control of the product and production process, and ensures the proper
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production environment. In addition, the company has also obtained the QMS ISO 9001:2000 certificate and others.
„All our actions are taken with our Customers in mind” Top marks of the certificates owned by the company, ongoing activities focused on the development of company’s Employees, and concern of the machine park are important, but not the only actions, taken by RUN Chłodnia we Włocławku Ltd. to ensure full Customer satisfaction. The next step is a constant broadening of the company’s assortment, within which we can find a huge range of products purchased in a variety of product lines. The company’s frozen food and ready meals are divided into three segments: ready-made meals and snacks, fruits and vegetables, ice cream and desserts. RUN Chłodnia we Włocławku Ltd. provides, inter alia, bacon wraps, potato boats, cordon bleu, prawn wrapped in bacon, meat, fish and vegetable shashlicks, mozzarella shashlicks, cabbage rolls, meat rolls, green beans in bacon, goulash, letcho and many others. The company has also a very wide range of processed vegetables and fruits. “Know Good Food” Certificate has been received by frozen vegetables and fruit, as well as multi-component mixes from the Bolero series, manufactured by RUN Chłodnia we Włocławku Ltd., part of RUN Group. The certificate is an annual award, granted by the Ministry of Agriculture and Rural Development to distinctive food products. The prize has been granted to frozen vegetables and fruit, as well as multi-component
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mixes: broccoli and cauliflower florets, carrots, cut green beans, multi-component mixtures of vegetables and strawberries. The mark was given for a period of 3 years. The Bolero brand products consists of: BOLERO series – frozen vegetables, fruit and multi-component mixtures, BOLERO PREMIUM series – frozen ready meals, corn cobs and BOLERO ice cream and desserts, as well as the latest series of products – BOLERO ORGANIC – frozen organic products. Bolero brand products are based on carefully selected raw materials from Warmia and Mazury, Polish region famous for its ecological values, which ensures the highest quality of offered products, as well as guarantees their exceptional value of health and nutrition that will satisfy the most refined taste. By deciding to purchase frozen fruit and organic vegetables, the Customer can be assured of the highest quality: without chemical fertilizers and pesticides, as well as without the use of genetically modified organisms, growth hormones and antibiotics. Deep-freezing of fruit and vegetables extends their shelf life and does not require preservatives, colours or oxidants. Temperature alone effectively stops the growth of mold and bacteria. Iwona Pavlovic, famous Polish dancer and dance coach, is the Bolero brand ambassador. All Bolero products are signed by the “Black Mamba” and, in addition, the company has introduced a special line of products, recommended by the Bolero brand ambassador - “The Composition of Iwona Pavlovic.” To strengthen even further its competitive position, the company has invested in TV advertising – the most effective form of advertising by
far, especially, when the goal it to reach as many Customers as possible – maximize the content, minimize the needed time. “Do not pull the Mammoth – buy frozen Bolero” is the latest and innovative advertisement of the Bolero brand. Fully individual approach to each order, a very accurate selection of suppliers, extensive customer service in the company, excellent use of the enormous agricultural potential of the Kujawy region, where the company’s crops grow, are another factors, thanks to which the company has started a business cooperation with globally recognizable Recipients, such as KFC, Pizza Hut, Burger King, Morrison’s chain, Netto, Aldi and other super- and hypermarkets. The company also conducts extensive marketing activities, monitors the ever-changing market conditions, participates in international trade fairs ANUGA in Cologne, SIAL in Paris and ProdExpo in Moscow.
Summary
RUN Chłodnia we Włocławku Ltd. is proof that a comprehensive development plan, implemented consistently and with a deep sense of responsibility in all aspects of work, ensures success, of which many other companies, not only from the food processing industry can only dream about. Given here solutions, used by the company require significant skills and considerable resources, but summa summarum, they result in the birth of a truly strong company with excellent prospects for development. Written by Jacek Głowacki
ARTICLES |
Consumer GoodsHuta Szkła Gospodarczego Tadeusz Wrześniak
Trend of contemporary beauty
F
rom the moment when mankind started to settle, about 10-12 thousand years ago, completely new activities gained particularly special importance, generally affecting the directions of development of civilizations, the strength of the various tribes in the neighborhood, and even the emergence and flourishing of ancient empires. I am speaking of course of agriculture and animal husbandry, development of pottery, a craft, through which we have managed to discover a completely new use for, perhaps the most seminal invention in human history, the wheel, as well as metallurgy, art, responsible for forming ever new and finer weapons. However, there is a special branch of metallurgy, not engaged in the processing of raw materials extracted from the bowels of the Earth by miners, but the creation of a truly beautiful, delicate and fragile expressions of talented craftsmen. Glass has become a source of wealth for many cultures, and pieces of art made of glass are joy for the eyes and soothe the senses of people regardless of their traditions, language they use, the gods, they believe ... I have the honor to present the organization, whose name has become the synonym of glass art, delicate beauty of the highest quality: Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. A company different than others
When I was analyzing the history and specifics of activity of Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o., I could not believe that one man, thanks to his determination and organizational skills he was able to resurrect the Polish glass industry, whose situation during the period of transformation after the fall of communism in our country was truly miserable. Tadeusz Wrześniak was not only able to restore the splendor of many bankrupt, though often famous industrial plants in Poland, but also but also proved to be a real savior
for hundreds of people, who lost their jobs, as a result of inefficient management of the centrally planned economy. The uniqueness of HGS’s owner can be proved by the fact that already in 1977 has he started his own business, what in the eyes of the socialist government was basically equal to treason! History agreed with Tadeusz Wrześniak, whose firm flourished when socialism in Poland has lost long ago its raison d’être. The official permission, needed to start Huta’s activity was granted in already independent Poland: on the 10th March, 1993. Tadeusz Wrześniak has already
Owner Tadeusz Wrześniak
FACT BOX
FULL NAME: Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. PRESIDENT: Tadeusz Żurek OPERATIONS: Glassworks ESTABLISHED: 1993 EMPLOYEES: 3450
www.glassworks.pl
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enjoyed his well-deserved reputation of manufacturer of high quality glass and a man of honor, who managed to start production, using newly-built glass bath in adapted premises of the former GS in Ładna and hired unemployed Workers of bankrupting Huta Szkła “Laura”. The next years were the era of intensive development of an organization, whose
reputation was about to cross the borders of not only our country but Europe as well. In 1995 Tadeusz Wrześniak purchased a bankrupting Huta Szkła “Dąbrowa” near Lublin, but he was also building new plants, completely from scratch, like in 1997 when, in the village Jarosty near Piotrków Trybunalski, the company needed just five months to start production. Over the next few years, the company operates a number of investment, thanks to which it quickly becomes the dominant producer of glass in Poland. Particularly noteworthy is the fact that the aid offered by Tadeusz Wrześniak in various parts of country, wasn’t limited only to infrastructure, but also concerned the Employees. Tadeusz Wrześniak always offered employment to people whose jobs went bankrupt, so the company can boast an experienced
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crew, strongly attached to the company. Although Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. can easily compete with the companies placed in Western Europe, the organization does not resemble in any way companies, concentrating on mass production, offering the same palette of products. Faithful to the secrets of the art, the company cultivates the best traditions of Polish glass industry. It is worth noting that Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. based in Ładna near Tarnów, in Małopolska, consists of several plants, located throughout the whole country offering top quality products, covering possible glass object that we can only think of. In Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. everything is possible!
Tradition and modernity under the same roof I have already mentioned the philosophy of work that distinguishes Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. from competitors and is one of the most important reasons why the company is on the rising wave for more than 30 years. I have also written few words about the company’s Employees, who owe a lot the organization based near Tarnów. Just like in any other organization in the world, Huta’s crew is the most important element of the company, and it is worth noting that it would be hard to find a group of Employees, better prepared for their tasks, then those working in HSG’s plants. This is due to the specific profession of
GLOB-TRANS Sp. z o.o.
www.glob-trans.pl
The basic profile activity of company is transportation services. Our company has at it’s disposal about 35 transport units and co-operates with about 200 companies in the country and abroad. By realizing our aim we create concern manged in a modern way. The company is popular with using advanced tools and technology in daily work. Received orders are realised by our own targets with helpful co-operators. Due to the insurance policy Your goods are safe during the transport. We are able to ensure : In addition we have a full range of various vehicles: tilts, frigos, mulds, semitrailers for over dimension cargos Road trains Trucks for small cargos On time delivery Experience Professional services
Glob Trans Sp. z o.o. 31 - 314 Kraków ul. Zygmuntowska 33/5
Glob Trans Sp. z o.o. ul. Drogowców 2 28 - 200 Staszów
tel/fax: +48 15 864 47 38 mobile: +48 509 860 388 e-mail: biuro@glob-trans.pl www.glob-trans.pl
Miś Transport i Spedycja specializes in: international full truck load transports (FTL) oversize transports silo transports part load transports Tel: +48 14 633 22 02 Tel:+48 14 633 05 31 Fax +48 14 633 22 08 www.mistransport.pl mis@mistransport.pl
WE OFFER MORE FOR ALL WWW.MANUFACTURING-JOURNAL.NET
Manufacturing-Journal | 41 |
Huta’s professionals, who, more than any other craftsmen, are artists, and characteristics such as creativity, experience, artistic imagination and manual skills affect more than anything else, the class of fragile, delicate product made of glass. Thanks to reasonable HR policy, Tadeusz Wrześniak managed to hire, counting more than 1000 people, team of professionals, who identify with the company and use their unique skills to achieve the top quality glass. Although in Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. are used the same production processes, which do not differ much from those used hundreds of years ago, the glass is still produced manually, making each item unique and exceptional, the company’s authorities invest heavily in new technologies and machines. Excellent, latest generation machines guarantee to maintain the highest product quality and production flexibility: another distinctive feature of Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. Most manufacturing companies is based on a similar principle: to prepare a product offer and use a variety of ways to encourage Customers to purchase them. Tadeusz Wrześniak’s company operates a little differently. One could say that it literally serves the Customer. Thanks to exceptional skills of Employees and advanced technology, it is in fact able to create any item
of glass in the desired form, color and ornament, in any amount and any time, guaranteeing the fulfillment of quality parameters of manufactured products. The creative potential of Huta’s Employees is unlimited. The company is also
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able to gain Customers’ trust, through almost unimaginable production flexibility and excellent service. There is no contract that company wouldn’t be able to realize, even if it meant the need to deal with new production techniques in a very short time! All of this is an expression of passion and love for glass: feelings, without which neither craftsman could become an artist.
Designing the future
Courage. It is a key-word that determines all HSG’s activities. Since 1993 the company sets the trends and directions of development of the global glass manufacturing. 90% of the factory’s products is exported, the brand is known on the markets throughout the world. Continuous searching, drawing inspiration from the millions of Customers, constant cooperation with the best designers, observation, but also the creation of the changing patterns of the beauty made of glass, of forms, colors, ornaments. Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. was the first glass manufacturer in our country that has understood the uniqueness of the industry and built its success on this understanding. The company’ products are appreciated not only at prestigious fairs – Ambiente and Tendence in Frankfurt, where HSG has debuted already in 1996 – but also organizations, awarding the most vibrant and effective companies.”Złota Firma Województwa Małopolskiego 2002”, “Wybitny Eksporter 2009 and 2010”, “Lider Polskiego Eksportu 2009 and 2010” are just a few of many awards and prizes granted to Huta Szkła Gospodarczego. We live in times of mass production, cheap trinkets we throw away away without regret when they are broken. Happily, there are still organizations, for whom tradition, good practices and Customer mean more than just advertising slogans. When the last such company will disappear from the face of the earth, it will mean the end of the high quality products. Luckily, it is a distant prospect for as long, as there operates Huta Szkła Gospodarczego Tadeusz Wrześniak Sp. z o.o. Such a company simply deserves to be successful! Written by Jacek Głowacki
ARTICLES |
Timber IndustryReni Ettore
100 years of experience and love to one’s work FACT BOX
1
00 years of experience and love to one’s work - a key to success of Reni Ettore S.p.A. Enzo Reni, the President of the family-run business with a long tradition shares his visions in the exclusive interview with Manufacturing Journal.
FULL NAME: RENI ETTORE S.p.A. PRESIDENT: Mr Enzo Reni OPERATIONS: Production and trade of plywood panels ESTABLISHED: 1959 EMPLOYEES: 287 TURNOVER: 70 mln €
www.renicompensati.it
From Father to Son
Reni Ettore S.p.A. is a leading Company in the wood sector specialized in the production of raw and laminated plywood panels. It is based in Volta Mantovana and is a typical example of well-prospering family business. They made their first step in the field at the end of the 19th
century when Giovanni Reni started to work the wood in a packing company in Luzzara (Italy). Next generations of the Reni’s family continued to strengthen the Company and extended its activities to other sectors. The adventure with the production of plywood started in 1959 and in 1990 current President, Mr Enzo Reni, founded the Société de Placages Châtillon Sur Seine specialized in poplar veneer production, a company directed by his son, Mr Nicola Reni. The total production of plywood is now about 90.000 m³ and the President hopes that the tradition will continue even when, in a 5 or 10 years’ time, the Company will be under his son’s management.
Company with Values
President Reni believes that the key to success to which the Company owes over 100 years of continuing growing
Manufacturing-Journal | 43 |
and developing is “experience, love to the work you do and a vision not only for your local area but for a whole world and for the sector network.” A very important element is a sense of duty and a care to provide the customers a service and products of the highest quality. The Company has the personnel of almost 300 people consisting of both office and factory workers. Mr Reni is very proud of Reni Ettore S.p.A’s policy regarding the relationship between the employees and the Company. During the struggles between the Trade Unions and working class which took place in Italy in 70s and 80s the Company tried not to get involved and to keep good relations with employees. Only a couple of strikes took place. It’s an instrumental thing to have love and seriousness towards the customers and also towards your own employees.
Always Stay Updated - a Key to Success In the recent past Reni Ettore S.p.A. invested in machines and fields of production connected to shipbuilding and furniture for caravan-campers. They use systems which represent one of the most technologically advanced patrimonies in Italian and world market of the wood sector. The Company also made significant investments in energy conservation: they are completely independent in the field of electric and also thermal energy using their own boilers. On the other hand, it is necessary to invest in new technologies, according to the requirements of the market, customers and sector, aiming to reduce costs, as lean production is another crucial factor on the way to success. In Mr Reni’s opinion the most important way to stay updated about the newest trends and innovation in the sector is to keep a permanent contact with the world and to
| 44 | Manufacturing-Journal
observe what is happening in the market. “There is a need to come out of your own country to abroad”.
Variety of Products
Reni Ettore S.p.A. offers a range of products able to satisfy the different demands of customers. The biggest part of Company’s products is made from poplar wood, deriving from a careful selection of poplar trees and from an accurate control of the different working stages. Poplar is a plantation tree with special characteristics: it grows in a 10 years’ time and it is typical of the areas rich in waters. Its simplicity of cultivation makes it the perfect tree for industrial use. In the full offer customers can find poplar plywood (trees of the Po Valley, Friuli Venezia Giulia and France), exotic wood plywood (Okoumé and Ceiba) and laminated panels. On the official website customers can find all the additional details about the presented products.
The Conquest of the Market
Reni Ettore S.p.A operates for a 50% in the Italian market and for another 50% mostly in the German, English, Dutch, Belgian, American, Australian and New Zealand markets. Their products are present in five continents. T hey are the leading manufacturer in Italy and one of the biggest in Europe. Asked who are his most important customers Mr Reni replied that “it’s difficult to speak about names. I see it more like sectors. In Aus-
tralia and USA it’s camper caravan sector and in Europe furniture and shipbuilding”. Unfortunately the crisis touched also the wood sector and as the President says in Italy the market collapsed of 70% what was strongly felt in business. Hopefully in the international market something started to move on now, mainly in the camper and shipbuilding sectors, which makes Mr Reni optimistic, especially because of his particular interest in this two fields. In his opinion contact with the outside world is very important and despite the fact that the Company does not think about the expansion at the moment, the President sees interesting opportunities coming from the development of foreign markets. “I hope the world recovers. We have to expect the progress from the Orient: China, India, Korea, Vietnam and from
ficial website you can find the current list of all certifications among which the ecological mark PEFC, as well as the certification for the management system of quality which is in compliance with the standard UNI EN ISO 9001: 2008.
Hopes for the Future
Apart from the before mentioned crisis issue, President Reni hopes that the Italian market can be sustained politically though some economical and social measures: the aim should be to reduce bureaucracy and to help companies to boost their production, in order to keep the Italian-made product competitive and up-to-date. Written by Kinga Nykiel
Africa. There are 6 billion of habitants in that area between Asia and Africa and we wish some progress there. For now however, we concentrate on fighting the crisis on the markets in which we already operate.”
Certificated Quality and Respect for the Environment The Company guarantees to its customers the highest level quality attested by various certificates and awards. As stressed by president Reni, “the Company needs certificates in order to be able to respond to all requests from all over the world”. They can boast about certificates of all types, for both American (CARB2) and European markets. Since January 2010 all the plywood manufactured in Volta Mantovana can be distributed with the CE certificate. They have received also the Catas Quality Award certification Formaldehyde E1 for the low formaldehyde release characteristics of their plywood panels. On the of-
Manufacturing-Journal | 45 |
ARTICLES |
Construction & Furniture IndustryKronospan Szczecinek
With respect for nature
W
hen Barack Obama, at the beginning of his path to presidency, presented a large – scale plan to get the U.S. economy out of the devouring abyss of the financial crisis, he emphasized two particular elements of this plan: deeper than before state’s involvement, as a controlling entity of the economy of the country, and a project of its stimulation, among others, through a series of government orders, oriented around the powerful green investments. Obama’s “green politics” as a strategy for spending public money, has become, at least on paper, the best manifestation of the aspirations of societies in developed and developing countries, leading to the restoration of ecological balance on our planet.
Slowly awakening ecological awareness is reflected in many political and social initiatives, as well as in the growing strength of green non – government organizations, however, the restoration of this harmony, depends to the greatest extent on the policies of large manufacturing companies, as the potentially major emitters of harmful substances into the atmosphere. However, before people began to realize the dangers of immoderate exploitation of natural resources and the scale of industrial pollution, there have already existed companies, which set concern for the environment among its priorities. And though the path to achieve perfection in this regard may be winding and riddled with obstacles, it is worth taking the challenge and incuring expenses, and, while commiting mistakes, one also needs to be able to draw appropriate conclusions from them. Let’s take a look at the history of Kronospan in Poland – a group of companies that have always emphasized the green aspect of the business, and were able to draw such conclusions.
Presentation of the company
Kronospan in Poland was created in 1989 on a wave of economical and political transformation after the collapse of communism, as a result of the deep transformation of pre-existing Zakłady Płyt Wiórowych in Szczecinek. Although each company could be proud of two decades of activity marked by constant growth, Kronospan Szczecinek Sp. z.o.o. boasts much more than that. The organization is a part of the mighty Kronospan Holding, operating in seventeen coun-
| 46 | Manufacturing-Journal
tries worldwide, employing more than ten thousand employees. And although the Kronospan company was founded as a family enterprise already in 1897 in the tiny Austrian town of Lungötz in the region of Salzburg, 56% of current revenues from the sale of products is the result of an active business establishments in Central and Eastern Europe. Over a century of experience in all areas of business management, strong support of others Kronospan manufacturing facilities, reaching billions of dollars investment to modernize machinery and specialized tools, and achieve the highest quality products and services, while taking care of the natural environment and well – being of local communities. All these factors led to the creation of the world’s largest producer of MDF in raw and melamine – faced versions, as well as chipboards in raw and melamine – faced versions, wall panels and lacquered HDF boards. These products, known for its quality of craftsmanship, original design and great style, build Kronospan brand. Among the company’s Customers we can find companies working in the construction industry, manufacturers of furniture and individual clients from all around Europe.
Mission and advantages
Representatives of the company do not conceal that the greatest ambition of the firm is to take the position of a global leader in efficient production of wood – based materials. The privilege of naming itself a leader in any field, however, means a great responsibility. Efficient production means not only minimizing costs and increasing revenues,
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but also being able to make accurate and rational decisions in all aspects of the organization’s activity. Kronospan in Poland, which consists inter alia of manufacturing facilities in Szczecinek, Poznań, Mielec, Pustków and Strzelce Opolskie, appears to be an organization which does not lack the skills to take up the challenge. The basic requirement of every Kronospan’s Customer, is the highest quality of purchased product, and the achievement of this state is possible only through the most professional and well trained Employees. Thanks to constantly updated procedures and internal system of training, Kronospan Grupa Polska managed to create an impressive staff of two and a half thousand Employees, perfectly prepared for their tasks, at every level of the company’s structure. Another advantage, crucial
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for the success of the organization, are relevant investment, directly linked to the park of machines and technological advancement of the production plants. The accumulated value of Kronospan’s existing investments is approximately 6 billion Zlotys, which places the Group on the 13th place on the list of the biggest foregn investors in Poland (according to The Polish Agency of Information and Foreign Investment). As part of this huge investment Kronospan restructured its manufacturing plants and built another, implemented the latest production standards, and know – how, and finally purchased the most technologically advanced production lines, machinery and specialized equipment. The line for the production of HDF panels in Szczecinek, or the process line for production of decorative paper in Poznań, are just examples of the most modern solutions not only in Poland, but globally, impemented by the company to optimize the production process. Thanks to huge financial possibilities, and their skillful utilization, Kronospan in Poland boasts large range of products offered under several brands, as well as enormous flexibility in the realization of both production and post – production services. Due to successful implementation of the policy mentioned above, the company is able to maintain the highest level of competitive advantage, and this in turn translates to the achievement of the company’s final aim, which is a full satisfaction of a Customer, who can be assured of not only the best quality of a requested product, but also its durability, perfect execution in relation to individual needs and fair price. Needless to say that prestigious certificates owned by the company guard the best possible standards of production processes, safe-
ty of work and other areas of the company’s activity. These documents include hygienic certificates of all the products offered by the company, as well as ISO 9001: 2000 Certificate for maintaining quality management system, and, successfully recertified for many years, SGS document for using the forest resources correctly, which is a part of participation of the company in the Forest Stewardship Council program.
Green policy and CSR
From the beginning of its activity in Poland, Kronospan was transposing the Western environmental standards, as well as CSR activities. The company chose the location of their plants from Szczecinek, through Mielec, Pustków and Rudawa, to Strzelce Opolskie, paying special attention to the economic situation of individual regions, trying to choose those areas which were particularly affected by high levels of unemployment. But the fight against unemployment alone is not enough to call a business socially responsible. Therefore, Kronospan has started a series of actions, aimed at the development of local communities. The company began to implement its own programs of social communication in order to accurately understand the needs of residents of the region, and fulfill those needs. Evidence of this is the material and organizational support to a number of local initiatives in such important areas as health, education and culture, the purchase of specialized equipment, such as ambulance, fire truck, or cardiomonitor, as well as a special treatment of the company’s Employees, who, except the basic social package, also receive many additional benefits. Such policy resulted in a pres-
tigious award, granted to the company many times, which is the “Fair Play Company” title, as well the “Pillar of the Polish Economy”. The organization also conducts large – scale charity. The measure of company’s greatness are not its successes, but how it acts in difficult situations. Kronospan approaches responsibly to all matters related to its business activity, paying particular attention to environmental aspects. This sentence also refers to Kronospan, whose actions resulted in some opposition of the representatives of local communities, paradoxically, in the context of the threat that these actions were to be for the environment. Kronospan however did not barricade itself from the media, but has taken all efforts to explain those allegations. A company that fits the philosophy of dialogue in its activities, respects the opinions of specialists, while stressing its non – negotiable commitment to the ecological dimension of business, certainly deserves respect. Participation in the Forest Stewardship Council program, careful selection of the company’s Suppliers, and annual, multimillion –
dollar investment in order to conduct production activities while maintaining the deepest concern for the environment, are all evidence of Kronospan’s green politics. If Kronospan will be able to maintan existing high standards in all areas of business, and even raise them, and will not lose its precious dialogue skills, and the ability to draw right conclusions, then the future of the company seems truly bright. Written by Jacek Głowacki
Manufacturing-Journal | 49 |
ARTICLES |
Construction IndustryOpal
A black pearl among enterprises
O
pal is a beautiful mineral, a precious stone adorning crowns of the most powerful monarchs in history and also the official symbol of Australia. Opal occurs in many types and variations on almost every continent. Although it was loved even by the ancient Romans, it never managed to conquer the imagination of masses, always remaining in the shadow of diamonds, emeralds or rubies. It seems that the founders of Opal sp. j. in Grodzisk Wielkopolski did not choose such a name by incident. The management philosophy of the company from Wielkopolska is characterized by the equally beautiful qualities as the endlessly changing colors of precious stones, which we cannot stop looking at. The opal has not taken its rightful place in the history of literature, read by the boys, entering the youthful age, with flushing cheeks, Opal on the other hand, can be as fascinating, as the adventures of pirates, roaming the Caribbean Sea in search of black pearls...
A rough diamond
If we analyze the history of Opal sp. j., we might be surprised by the growth rate of this, inconspicuous no to so long ago, company. In twenty years of operation, the company changed almost completely, except the owners and their management philosophy, which is the basis of the Opal’s success, a guarantee of an effective development of the company, and a lesson that should be learned by all the entrepreneurs, dreaming to go in the footsteps of the company from Wielkopolska. The history of Opal sp. j. began in 1991. Poland was entering a difficult and full of sacrifices period of transformation, characterized by a lack of economic stability, a very high level of inflation in the early stage and a huge increase in the number of private companies sprouting like mushrooms after rain, and quickly bankrupting. In such a reality a small, familyowned company, named Opal s.c. was founded, employing five people, including owners. At that time Opal, like many other companies in our country, was a manufacturer of doors and windows. Knowing the economic characteristics of the province of Poznań, which now is a part of the larger Wielkopolska voivodship (Opal’s headquarters is placed in Grodzisk Wielkopolski, the charming little town near Poznań), the choice of the business activity should not be surprising. On the other hand, it is worth taking a closer look at the history of the company to understand how it managed to develop a strong market position in a very competitive environment. Especially because Opal s.c. was characterized
| 50 | Manufacturing-Journal
from the very beginning of its existence, with a very fast pace of development, expressed both in the constant increase of employment rate and production capacity, but also in continuous expansion of product offer and learning the principles of company management according to patterns flowing into our country from the West. All these factors led to a complete transformation of Opal. At the moment Opal sp. j. is one of national leaders, specializing in designing,
FACT BOX
FULL NAME: Opal Sp.j. PRESIDENT: Ryszard Szulc
VICE PRESIDENT: Wacław Olejniczak
OPERATIONS: Glass facades ESTABLISHED: 1991 EMPLOYEES: 120 TURNOVER: 14.000.000 EUR
www.opal.com.pl
erection and the assembly of modern elevations, performing constructions in public utility buildings, office buildings, commercial facilities, universities and private objects.
A diamond in all its glory
As mentioned earlier, the initial phase of Opal’s activity occurred in the 90s in Poland, an era called “wild capitalism”, in relation to the economic situation. There is a reason some American and Western journalists write about Central - Eastern Europe in the last decade of the twentieth century, using the term “Wild East”. From the sea of the emerging enterprises, only the strongest survived, those, who were able to provide the highest quality products and services for a relatively low price, those, who managed to meet the requirements of new Consumers. For various reasons, Opal sp. j. even then turned out to be, a special company, clearly marking its presence on Polish economic map. Let us examine the solutions used in the company from Wielkopolska to understand why
Opal manged and still manages to be successful on a large scale. The basis for successful development of all organizations, regardless of the industry in which they operate, are their Employees. Within two decades of work, Opal’s number of Employees increased from five to more than 130 people. Effective HR policy based on the philosophy professed by the organization, ensures the harmonious development of the company and allows Employees to feel satisfied. Besides the obvious solutions, implemented today in almost every organization, such as extensive training and courses to increase skill levels, both hard and soft, Opal’s personnel policy is pervaded by a philosophy, inoculated by the owners at the beginning of business activity. It attaches the greatest importance to communication, unlimited exchange of information, allowing the company to learn and realize the needs of both Employees and business partners. Building long-term relationships based on mutual respect and understanding another’s perspective, is crucial to successfully build the image of the or-
Manufacturing-Journal | 51 |
ganization and its competitive position. The most important distinctive feature of this philosophy must be honesty and trustworthiness. Implemented for twenty years, such an attitude soon began to produce the desired effect. During the times, when mattered primarily the force of persuasion, and the procedures implemented by the competing companies were far from fair and transparent, the philosophy held by Opal sp.j. was far ahead of its time, reflecting an unprecedented level of its owners’ business acumen. Finally, the owners’ assumptions proved to be correct and led the company to the very top. Of course, the philosophy alone, regardless of the values on which it is based, will not ensure the full success of a commercial organi-
zation, although in the case of Opal, it is undoubtedly its foundation. The company operates in a highly demanding building industry, and is present on saturated markets. Therefore it must above all provide the highest quality products and ensure timely deliveries. To achieve this goal, it is necessary to have not only well prepared team of professionals, but also adequate, modern technology. Opal sp.j. boasts both one and other. The company carefully selects materials needed in the production process, uses only the services of reliable suppliers, works with the best general contractors. This positive elitism, coupled with an individual approach to every contract
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guarantees achieving the company’s ultimate goal: total Customer satisfaction. The requirements of the XXIst century, supported by the assumptions of a philosophy based on honesty and integrity meant that in his quest for perfection, Opal sp.j. reached a position of one of the most desirable business partners in our country. List of projects in which Opal was involved is impressive.
A black pearl among enterprises
Opal’s uniqueness lies also in the fact that already in the 90s, it has already implemented environmental and CSR policy, when nobody in Poland knew anything about these concepts. Efforts focused primarily on training and devel-
oping Employees, listening to the needs of local community, a wide range of activities aimed at integrating Employees and provide them with a sense of social and financial security, as well as optimizing production, while taking care of the environment, coupled with the highest
quality of products and services and the philosophy of cooperation and fairness have been recognized and appreciated by prestigious organizations that award the most valuable representatives of Polish business. Among the honors we can find, inter alia, the “Teraz Polska” statue, Business Centre Club’s award, the “Company without Barriers” title, honoring companies supporting Employees with disabilities, 1st prize in the “Wielkopolski Lider Społecznej Odpowiedzialności Biznesu” contest and twelve “Fair Play” awards, as well as many other medals, trophies and diplomas earned at numerous trade fairs. Opal sp. j. is growing dynamically, as it did since the very first day of its existence, is considering expansion into foreign markets, plans
to create another branch of business, so it could become even more desirable business partner. The world around us is changing very rapidly, changing for the better. Let us remember that also thanks to Opal sp. j. Written by Jacek Głowacki
ARTICLES |
Construction IndustryInter-System
Expert in construction
I
nter-System Sp. z o.o. is a construction company which entered the Polish construction market around 20 years ago. The economic changes in the wake of the transformation which Poland went through in the 1990s. provided favourable conditions in which the company could be established. Nowadays managed by Marek Nowara, the chief executive officer, and Lech Piński, the vice president, the company defined its objectives after two or three years of trials and errors. The enterprise specializes in executing projects commissioned by the public sector institutions, not as their subcontractor, though, but primarily as the executor of the investor’s orders. It is also worth noting that Inter-System has adopted the idea of development based on increasing its market share in a manner as safe as possible.
Chairman of the board Marek Nowara
Among the company’s customers one can include local governments, colleges, hospitals and other health care institutions, government agencies, private natural and legal persons. About 15 % of orders consist in the execution of real estate development projects. To this, one should add the execution of maintenance or reconstruction of historic buildings and monuments, the construction of cultural and educational institutions’ edifices, along with investments in new objects, such as college buildings, offices, and research institutes. InterSystem Sp. z o.o. executes investment projects in the construction sector in a comprehensive manner: from carrying out preliminary measurements, through designing and constructing a building, up to obtaining permission to use the building for the subject who ordered it. The unique characteristic feature of the company is the combination of the organizational structure of a corporation with a special focus on interpersonal relations, stress being put on subjective treatment of each person person working for the company. Owing to the perfect integration between the owner, the management and the employees, as well as mutual interactions between the diverse levels of the organizational structure of the enterprise, it becomes easier to work out common success and prosperity.
Professional organization and logistics system In our times, construction does not boil down to construction engineering alone. It also, and perhaps most impor-
tantly, rests on logistics. It comes down, in its essential part, to financial engineering and professional organization of the enterprise which, besides, has a high degree of mobility. Due to the company’s effective logistics system, it is capable of carrying out up to 20 construction investments at one time. It is the organizational capacities of the company’s managers that the constant development of the enterprise should be put down to, considering the fact that the enterprise started as small and after a few years
FACT BOX
FULL NAME: Przedsiębiorstwo Budowlane Inter-System Sp. z o.o. CHAIRMAN OF THE BOARD: Marek Nowara OPERATIONS: Construction ESTABLISHED: 1989 EMPLOYEES: about 300 TURNOVER: 110 mln PLN (2010)
www.inter-system.com.pl Manufacturing-Journal | 53 |
became medium-sized. The number of people employed, though, does not always reflect the company policy and the principles upon which it acts. At present, around 300 people work towards the success of the company, even though there were times when Inter-System Sp. z o.o. employed as many as 500 workers. According to Marek Nowara, the company’s CEO, it is pivotal for the enterprise to be able to react and adjust its actions to the dynamically changing tendencies and requirements of the market. Therefore, maintaining human resources as such does not provide the main objective of the enterprise; rather, the point is that the company’s current human resources should guarantee its effectiveness whenever required. Thus, for instance, when a subcontractor fails to complete his task, the company employs additional new workers for a determinate period of time. Importantly, Inter-System applies the same policy to its employees as it does to its equipment and facilities. Namely, underlying this policy, one can find the conviction that both the staff and the equipment should be involved in the company’s operations in 100 % and 12 months per year.
Design, construct and finance
The past five years have proved an exceptionally beneficial period in the activity of the Polish construction enterprise. Acquiring experience, signing new contracts, employing some important staff – all these have made for the fact that Inter-System Sp. z o.o. offers more and more professional services, without becoming restricted to construction works but, most of all, paying attention
| 54 | Manufacturing-Journal
to the development of financial engineering. Undoubtedly, successful development of the enterprise hinges on the ability to properly understand the requirements of its customers. Today mere construction does not suffice, stresses Mr Nowara. Crucial is the project itself as well as financing the project. Maximum “packaging” of the investment process can be secured by the Design – Construct – Finance system. The idea behind the system is that the subject who executes the order accounts for the design and construction of an item and obtains permission to use it. The system is friendly for investors, as it allows them to avoid the risk accompanying the investment and, in addition, it reduces by half the length of the investment process, compared to the traditional procedure. By minimizing costs, it enables the bank to repay debts within the period of 5 up to 10 years. Whereas the system ensures the best conditions for the investor, it is slightly less convenient for the executor who always has to take account of financial indicators and financial resources at his disposal. There are a number of ways in which to raise funds: from commercial funds in the private sector, through creditor’s claims and solutions employing the PPP – in the local government and public institutions sector. InterSystem helps investors to find resources necessary to finance their investments. The Design – Construct – Finance system permitted realization of the following projects in Wrocław: the District Office (Starostwo Powiatowe) edifice, the Municipal Hall (Urząd Miejski) edifice, research facilities of the University of Life Sciences with its Centre for the Study of Food and Nutrition, and the Nursery.
With care about the natural and social environment Inter-System Sp. z o.o. strives to act in an ecologically responsible way on all the levels of its activity, even though it seems fairly obvious that there will always be solutions which are not entirely and absolutely environment-friendly. In 2006, the company purchased a sawmill in Bielawa, already existing for over 70 years, and transformed it into a wood factory of the Inter-System Sp. z o.o. Group. The factory delivers highquality materials which meet the current ecological standards. Applying the prefabricated timber roof trusses system allows to reduce the costs of construction at about 20-40 % in comparison with traditional roof structures; besides, it increases design safety and flexibility. Although the company does not have its own charitable foundation and does not engage in any special kind of activity outside the area of its specialization, it does react immediately to various social needs, related either to particular
emergencies, or activities within the domain of health care. Depending on the needs and requests, the enterprise provides help to private people – directly or through an institution. Adjusting its actions to current needs, Inter-System donates a considerable amount of its income (much more than 1 % from the income tax) to those urgently in need.
Successful past and plans for the future
Over the relatively short 20-year period of its existence, the enterprise has frequently been awarded with prizes for leaders in the construction industry. This year, Inter-System Sp. z o.o. has become the winner of the 4th edition of the Lower Silesia Economic Prize (Dolnośląska Nagroda Gospodarcza), granted by the Lower Silesia Marshal Office (Marszałek Województwa Dolnośląskiego) for the enterprises which contribute to the development and promotion of the region, which further initiatives and economy in the Lower Silesia. As Marek Nowara
remarks, prizes which one can be especially glad about are those which have come unexpectedly, without knowledge and conscious efforts on the part of the managers, since they testify to the recognition the company receives on the market. In particular, at stake is the Lower Silesian market where, for the most part, Inter-System operates, thereby contributing to the stable economic growth in the region. By creating new workplaces, the company also performs an important social function. One of the key factors behind the enterprise’s development amounts to its acquiring knowledge and exchanging ideas and experiences through cooperation with academic institutions. This proves exceptionally creative and motivating its further striving for improvement. Positive experiences in the Polish construction market determine prospects for the future of Inter-System Sp. z o.o. Introducing new solutions for investors, making easier the investment process, enhancing financial engineering and consulting, active participation in the PPP projects and the stock exchange – these are but several exemplary priorities of the company. Equally importantly, it aims at expanding its activities on other regions in Poland, apart from the Lower Silesia. For, last but not least, the Polish construction market enjoys really high economic potential. Written by Anna Tomaszewska
Manufacturing-Journal | 55 |
ARTICLES |
Construction IndustryPBG S.A.
The builder of Polish power and a patron of culture
P
BG S.A. is a leading company on the Polish market that has constantly dealt with designing, producing and repairing pipelines, facilities used for transporting petroleum, natural gas, water and sludge as well as heat engineering and gas storage infrastructure.
President Jerzy Wiśniewski
The debut at the Warsaw Stock Exchange on the 2nd of July 2004 was beyond doubt one of the most important moments in the history of the company. One of its results was gaining the capital of 96 million zlotys which enabled the development of the executive potential and winning most of the shares of Hydrobudowa Włocławek in the following year. At that point the future of the company was already presenting itself optimistic. Poland’s access to the European Union was a chance to gain a number of orders in the fields co-funded by the EU. In 2006 PBG S.A. acquired the shares of Hydrobudowa Śląsk and in 2007 merged it with the company Hydrobudowa Włocławek, creating this way one of the biggest economic entities operating in the area of ecology and
hydro-engineering in Poland. Establishing Hydrobudowa Polska opened a way to gain the contracts associated with Poland’s preparations to EURO 2012. The year 2007 was the moment of the purchase of Hydrobudowa 9 company which in the past was PBG S.A.’s actual biggest competitor in the ecology field. In 2008 PBG has gained the contracts to construct an underground gas storage facility in Wierzchowice and a LMG crude oil plant. These contracts were the most important undertakings in the history of the sector of natural gas and petroleum in Poland. Thanks to them, PBG is now the leader of the gas and petroleum market in Poland and executes the key investments that ensure the energetic safety of Poland.
FACT BOX
FULL NAME: PBG S.A. PRESIDENT: Jerzy Wiśniewski OPERATIONS: Construction ESTABLISHED: 1994 EMPLOYEES: PBG SA - 490, PBG Group - 3149 SALES REVENUE: PBG SA - 909 953 thous. PLN PBG Group - 2 740 311 thous. PLN
www.pbg-sa.pl | 56 | Manufacturing-Journal
The new, highly-modern sewage treatment plant „Czajka” in Warsaw
ny. What is more, PBG constructs three out of four EURO 2012 stadium contracts. By winning the contract for modernization of City Stadium in Poznań in 2008 the company entered the sport infrastructure market, in January 2009 PBG became the contractor of BALTIC ARENA in Gdańsk and in May 2010 it won the contract for construction of the biggest project – the National Stadium in Warsaw. Another milestone in the history of the company was the contract won in consorcjum for the construction of the LNG on-shore terminal – the first Polish liquid gas terminal in Świnoujście that is also the key element in the system of Poland’s energetic safety. This contract is one that has the highest single value in the history of Polish economy – 2.2 billion zlotys. The strategic move was to gain the first big road construction contracts and joining the group of companies taking part in building the
National Stadium in Warsaw
PBG S.A.
– contractor of Poland’s key projects PBG can be proud of the fact that it is the contractor of many projects of great importance to the country, being quality mark not only for the company but also for Poland. The year 2008 was extremely important and successful one for the company when, despite the global economic crisis, PBG signed two contracts with PGNiG and became the general contractor of constructing LubiatówMiędzychód-Grotów crude oil plant and of construction the underground gas storage facility in Wierzchowice, worth over 2,5 billion zlotys. Polish energetic safety depends on the completion of these two projects that is why they have an immense importance to the compa-
Municipal Stadium, Poznan
PGE Arena, Gdansk
road S5 and the sections of A1 and A4 highway, as well as commencing negotiations with the Spanish concern OHL. PBG wanted to open new possibilities of cooperation between these companies in Poland and all over the world by offering majority packages in ccompanies Hydrobudowa Polska SA and Aprivia SA to OHL. Thanks to OHL’s experience in that field PBG could enter the new markets such as Brazil or Mexico.
New challenges, constant development
Polish market of executive service in the gas segment is considered a very perspective one thanks to the expected billion zlotys investments related to the
Manufacturing-Journal | 57 |
Poland’s energetic policy and to the adaptation to the standards of European Union. The first step into the energetic market was the purchase of 25% of shares in company Energomontaż Południe S.A. and the next one – establishing the company PBG Energia responsible for the cooperation with the leading world companies of this sector. In May 2010 PBG signed the strategic agreement with ALSTOM, the world’s energetic tycoon. This will enable the companies to win the most significant contracts in the segment of energetic engineering in Poland. For the time being, the company tenders for the contracts in this market area of total value of 25-30 billion zlotys, which is only 16% of all investments by the year 2020. Among the further plans of PBG there is also an expansion on the international markets like Bulgaria and Romania and a new company, PBG Bułgaria, was established to help realize these objectives. The company is also interested in implementing its investments on the world’s biggest gas infrastructure markets such asNorway, Qatar and Brazil. Cooperation with the Spanish company OHL is going to help PBG to enter foreign markets. PBG is also preparing for tendering the contracts for construction and managing highways in Russia and Ukraine. Qatar is especially important for PBG for its investment plans before the FIFA World Cup in 2022. Qatar investors valued the PBG’s achievements and quality as a constructor of three stadiums in Poland. Qatar’s investment program plans the construction of nine new stadiums and completion of a number of other infrastructural investments.
Caring for the environment
PBG company takes part in developing the infrastructure of the country but it does not forget about the natural environment. The company develops the strategy of treating the environment according to legislative regulations and international ecological standards as ISO 14001 and SCC. Being aware of possible negative results of its actions, PBG takes care of all phases of execution of its projects to minimize the damage on environment. The company tries to involve in its pro-ecological actions not only its employees but also its subcontractors who execute the construction projects. PBG provides the system of lectures and courses that rise the ecological consciousness and knowledge of regulations. Ecological policy covers the area of the company as well as the site where the investment works are conveyed.
Social mission
PBG, as a social responsible company, makes a point of trying to act in a way that respects the values that are in accordance with its mission and vision. Since the very beginning of the company, the care of the environment, cooperation and charity were present in the strategy plan of development. The employees of PBG support and take part in various actions aimed at helping people in need. These are educational, cultural, art, sport and health events. Helping others, they always keep in mind that the most important is the fact of the selfless help itself. The employees often initiate charity campaigns. They engage as volunteers in cyclical actions, like ‘Wszystkie dzieci nasze są’ that every
year is an occasion to collect Christmas presents for children from the orphanages and indigent families, or ‘Nasze życie – nasze zdrowie’ – the campaign which aim is to build a bank of blood in the company’s ‘Bank Krwi PBG nr 200’ that in case of emergency can be used by the employees or members of their families.
Employees are the investment that always pays off
The cornerstone of the company is its people. This is why PBG every day does its best to keep the employees in a good form – physical and mental, organizes various events, trips and bonding days. Thanks to cooperation with Teatr Polski and Teatr Narodowy, the PBG’s employees can take active part in the cultural life of Poznań and the whole region of Greater Poland. All people employed by PBG can develop their passions and hobbies by joining numerous clubs and language school groups or even art galleries working within the company. The examples of such clubs are: Tennis Club ‘Return’, ‘PBG Sailing Club’, Fishing Club ‘Merlin’, music band ‘PBG Band’. The eactivity especially worth interest is the ‘PBG Gallery’ founded in 2002. Its curators are various artists, professors of University of Arts in Poznań. The Gallery gives a great opportunity of meeting the artists, their work and it creates an unique ambiance in the company and supports the promotion of culture in the Greater Poland. All these cultural actions undertaken by PBG prove that connecting business and art is possible. Written by Magdalena Urban
The Swinoujscie LNG terminal
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ARTICLES |
Engineering & Construction IndustryFluor
Corporate and Responsible
T
hey will help you turn oil into gold. Fluor’s credentials include more then 42,000 people delivering services to refining, petrochemical and energy industries all over the globe. The business takes on toughest challenges in engineering, procurement, construction, maintenance, and project management. It has also made its mark in Poland. Its Polish branch, Fluor S.A., carries on the tradition dating from 1945 and is counted among the biggest engineering companies in the country. Fluor’s Vice-President of the Board, Mr Grzegorz Czul, speaks exclusively to Manufacturing Journal about the company, its numerous prizes and its CSR policy.
History in Brief
Fluor’s Polish branch was set up right after World War II in Gliwice, Silesia. The city soon became an important academic and economic centre: it is there that the Silesian University of Technology was established. It is also there that design offices came into existence, primarily those serving the chemical industry. Among them Biuro Projektów i Realizacji Inwestycji was to be found, the main office for the reconstruction and development of Polish industry, preparing design documentation packages for the nitrogenous and phosphate fertilizers industry. In 1955, the office was divided into 5 different branches. “Hence Prosynchem came into being. Initially focused on chemical projects, it soon started cooperating with petrochemical industry. The list of its Clients was a long and glorious one, including Nitrogen Works in Kędzierzyn and Tarnów, factories in Chorzów and the Chemical Works in Oświęcim,” recalls Mr Grzegorz Czul. The years that followed brought the initial studies for the Nitrogen Works in Puławy. Subsequently, the office developed the entire plant there and supervised associated projects, which involved 18 different design subcontractors. In the meantime, the Gliwice office earned a pole position in terms of design methods and techniques and became the coordinator of operations for a network of design offices subordinated to the Nitrogen and Petrochemical Industries Union.
Global Network
By 1989 the office had specialised exclusively in designing chemical plants and petrochemical production. In 1990 the business extended its range of activity
with services provided to the refining industry. “Particular attention should be paid to the projects delivered to the Płock Refinery, including the hydro-cracking complex, asphalt oxidation, pipe-tower distillation and olefin production units. At that time the office developed vegetable oil production processes for the Czechowice Refinery and extended the Gdańsk Refinery facilities,” remarks Mr Czul. The 80s and 90s brought a massive change in Poland’s political and economic system. It seemed only natural that the office would be privatised before long. Consequently, in 1995,
FACT BOX
FULL NAME: Fluor S.A. PRESIDENT: Dave Gibson OPERATIONS: Refining, petrochemicals, chemicals, power, infrastructure ESTABLISHED: 1945 EMPLOYEES: over 280 INCOME: 28,4 mln PLN
www.fluor.pl Manufacturing-Journal | 59 |
Prosynchem changed hands and joined Fluor Corporation, which soon implemented its trusted standards: the Task Force Work Plan, complete computerisation and training sessions for employees in the US, UK, and Netherlands. Since 2003, the business has been renamed Fluor S.A., thus fully joining the network of Fluor’s global execution centres for international work-share projects, with engineering and procurement capabilities encompassing both FEED and DE across all disciplines. Thanks to this, Fluor S.A. gathered momentum to execute the following projects: the L154 production line for the Client in Scandinavia, including the detailed design, delivery completion and maintenance of the XLPE cable unit; the revamping of the LPG desulphurisation unit (study for Lotos S.A., Poland); the extension of gas complex forthe Client in the Near East (ECPM project executed in collaboration with Fluor Camberley, UK); the project for the leading Client in Germany: the consolidation of its 3 refineries to 2 different locations performed in cooperation with Fluor Haarlem, the Netherlands.
Competitive Edge
Fluor’s portfolio comprises complex engineering, procurement, construction, and maintenance (EPC&M) projects. As a multi-national company of the global range Fluor proves to be a partner to rely on, regardless of the location and type of technology. So far the business has struck deals with refining, petrochemical, chemical and manufacturing sectors. “The refining industry has grown to be our major Client recently. We do our best to increase cooperation with the chemical industry, too. We predict that our first full-scale projects should be well under way either towards the
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end of this year or at the beginning of 2012. Differentiated services will give us a competitive edge. Our top-notch quality has also helped us to win Clients in power, mining and biotechnology sectors,” elaborates Fluor’s Vice-President.
They Carried it Off
„How do define success? Above all, it’s Customer satisfaction. We are no easy rival to match in this respect and only few engineering offices in Poland can actually do it,” emphasises Mr Czul. A long list of prizes should convince even the greatest of sceptics. Some highlights of Fluor S.A.’s recognition and awards are to be found below: •
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The Corporate Social Responsibility Company of the Year 2010 awarded by the American Chamber of Commerce in Poland for its outstanding contribution to the local community. European Medals received from Business Centre Club in the years 2007, 2009, 2010 for general services, site maintenance and and EPCM (ang. Engineering Procurement and Construction Management) services respectively. Ambassador of the Polish Economy 2009 and 2010 for the best exporter and the Creator of 21st Century Solutions respectively. Golden Orbital 2006 and 2007 awarded for the high level of company organization and professional services. Business Partner 2010 handed by the President of the City of Gliwice for the support for many social initiatives and actions for children and youth. Caesar of Silesian Business 2008 and 2010 in recognition of local business leadership both in terms of
•
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the turnover and the impact on the community. Expochem Grand Prix 2008 awarded at the 1st International Fair of the Chemical Industry EXPOCHEM 2008 in Katowice, in the category Services for the Chemical Industry. Investor in Human Capital 2007 conferred on the select firms involved in HR-oriented actions and focused on good relations with their employees.
Together for the Posterity
Finally, an icing on the cake: the honours and awards granted by one of the company’s key business partners, Lotos Group S.A. The first of these was presented in December 2009 to Mr Marek Filipowski, the Director of the 10+ Programme project executed at the Gdańsk Refinery. The second award, Una Pro Posteritate, was conferred soon after that. “The former honoured our contribution to more than 20 different facilities, whose designing process was largely dependent on the work pace of other contractors and which nonetheless had to be completed on schedule. The latter was received for cooperation with Lotos Group, who belongs to our closest business partners and has been working hand in glove with us since 1993. Both these prizes demonstrate that we have all the necessary know-how, experience and technology and that we are able to execute EPCM projects comprehensively. We have come a long way to win these laurels. Now we can enjoy a lasting partnership with Lotos, the one that is built on mutual trust and respect,” adds Mr Czul.
Corporate Responsibility
“We aim to bea part of the local community,” remarks Fluor’s Vice-President.
Each year, the Fluor S.A. Charity Committee receives applications and makes donations to local day care centres, orphanages, schools, kindergartens, sport clubs, social assistance and cultural facilities. Fluor S.A. also supports the Habitat for Humanity organisation and the New Homes programme, which both aim to reduce housing poverty in Poland. The business contributes to the Building Futures scheme, providing backpacks filled with school supplies to children in 14 countries worldwide. “Likewise, we help kids in Gliwice, and the School Bags programme is exclusively dedicated to this end,” adds Mr Czul. “We are committed to the environment, too, and have taken part in the Greenpower Vehicle initiative and funded an electric car designed and executed by the students from the Silesian University of Technology.”
Fluor University
“Our employees can count on competitive rates of pay. We spare no expense, either, to provide them with professional training. Hence, we have come up with the idea called Fluor University. The scheme is available to all the members of our staff, which counts more than 250 people at the moment,” says Mr Czul. Fluor University offers specialized training courses in the latest design work management and organization methods, and professional software design tools. The programme includes: corporate training, internal training, including: induction, functional, on-the-job training and interpersonal training; external training, including: discipline seminars, conferences and courses. The major assets of the scheme are the Knowledge Online web-based system, Lunch & Learn sessions and Mentoring Circle programme.
For the Science
„Fluor seeks to support talented engineers in the area and has been cooperating closely with the Silesian University of Technology for a number of years. Thanks to this initiative, prospective engineers can gain hands-on experience and understand better what their future employers will require. We also invest heavily in both hardware and software for the students. We also support My Idea for a Business contest and the Greenpower Vehicle programme mentioned above,” adds Mr Czul. “Our specialists have access to top-of-theminute technology and serve the largest investors worldwide. It is exactly for our specialists that we celebrate National Enginers Week and organise the Fluor Friendly Competition.” Started in the mid 90s, this unique, global contest attracts teams from each and every Fluor office and project site. In the Gliwice branch, Fluor’s employees take part together with the students from local technical high schools and the University.
Comprehensive and Reliable
„Over the last 2 years we have learnt that only the fittest can survive on the market. To my mind, the fittest are those who combine a variety of services with top-notch quality. This is the only way you can earn Clients nowadays. We stick by simple philosophy: we perform our projects on budget and on time. We aim to be reliable and comprehensive and have been recognised as such by our business partners, employees and the Gliwice local community. We would like to maintain this reputation in the future,” recaps Fluor’s Vice-President. Written by Bartosz Sowiński
Manufacturing-Journal | 61 |
ARTICLES |
Energy IndustryFabryka Transformatorów w Żychlinie
A leader for ninety years
I
n the context of the operation of industrial plants, placed on the historical sites of the Łódź voivodeship, especially during the intensive development of industry in Poland, divided in the age of Partitions, in the nineteenth century, both in the city of Lódź, as well as towns located in its immediate neighborhood, two industries dominated primarily: the textile and mining (the largest brown coal mine is currently placed in Bełchatów). Awakening back to life after World War I, the Republic of Poland had to quickly and efficiently expand its production capacity so as not to stay behind in comparison to developed countries of Western Europe. One of the requirements during the second decade of last century, was the need for intensive electrification and although the gigantic project was not completed successfully due to the outbreak of the Great Depression and World War II few years later, the authorities made every possible effort to provide appropriate industrial facilities, necessary to implement the plan. This is why Fabryka Transformatorów in Żychlin Sp. z o.o., in the Łódź voivodeship, was founded. Ninety years of the plants’ history are equally fascinating, as their future... I sincerely invite you to read. FACT BOX
FULL NAME: Fabryka Transformatorów w Żychlinie Sp. z o.o. CHAIRMAN OF THE BOARD: Jadwiga Pawęzka OPERATIONS: Energy, Mining, Metallurgy, Construction ESTABLISHED: 1921
www.ftz.pl
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The dynamic development from the very beginning In the introduction above, I used the name Fabryka Transformatorów in Żychlin Sp. z o.o. for industrial plants, newly established just after the Great War. It is a deliberate lack of precision, used to highlight the current name of the company, which, in the course of ninety years, has changed its name several times. Originally, the plants in Żychlin, founded in 1921, bore the name of Polskie Zakłady Elektryczne Brown Boveri S.A. and were the first successful venture in general electrical machinery industry on Polish soil. Interestingly, unlike many other companies with
an equally impressive history, Fabryka Transformatorów in Żychlin, throughout the period of its activity, dealt with manufacturing products of a similar nature (including first tram engines in our country). The company’s offer has been, naturally, modernized and broaded over the years, but the organization itself represents the very same industry, which is of great importance for the present situation of the company. Of course, the fact that Fabryka Transformatorów works for nine decades means that it has survived perhaps the most dramatic period in the history of mankind, and certainly in Polish history. It is enough to recall only a few events in the life of plants,
to understand exactly what I mean. In 1931, Polskie Zakłady Elektryczne Brown Boveri S.A. was forced to suspend operations due to the effects of the global economic crisis. Two years later the company relaunched, but as Zakłady Elektromechaniczne Rohn – Zieliński S.A. During the Second World War the factory was completely subordinated to the German company, Brown Boveri in Mannheim. At the end of military operations, plants in Żychlin were nationalized, in accordance with communist ideology. As Zakłady Wytwórcze Maszyn Elektrycznych i Transformatorów M-1, the organization began its manufacturing activity on 15th March 1945, so two months before the formal end of the war in Europe! The most important domestic producer of electric motors and transformers was renamed in 1967 for Zakłady Wytwórcze Maszyn Elektrycznych i Transformatorów EMIT. After the fall of communism EMIT became, just like before the war, a public company, but excellent results, both in terms of sales, as well as quality caused that in November 2001 transformer plant was separated from the company structure, and so a new organization was created, under the name EV Żychlińskie Transformatory. The company operates under its present name – Fabryka Transformatorów in Żychlin – since April 2006. Regardless of the owner and name of the company, plants in Żychlin always offered highest quality machines manufactured and wide range of products offered to Customers. The company based in Żychlin has always been an important producer of transformers, not only in Poland but in Europe. Let’s look at the current situation of Fabryka Transformatorów in Żychlin Sp. z o.o. and we will see
that there is no indication that in future the company would have to deny its glorious history.
Modernity with respect of tradition
At the moment, Fabryka Transformatorów w Żychlinie Sp. z o.o. is a modern, well-equipped facility, in which the quality of both products, as well as Customer service, is no different in any way from Western European standards. This state of affairs is primarily due to a successful marriage of tradition and modernity in the company from Żychlin. The most effective use of rich experience in the field of production of transformers, coupled with modern methods of management in all aspects of the functioning of a modern factory, led to the identification of objectives, which the company should strive to achieve and allowed the development of methods and tools, which the company should apply to develop effectively and dynamically, just as for the whole impressive period of its past activity.
Achieving the objectives
The company’s authorities have defined very precisely the objectives of the organization. Like any modern company, which counts in the world, Fabryka Transformatorów concentrates all its activities to ensure Customer satisfaction. To achieve this basic objective, Employees make every effort to make sure that all the products manufactured in plants in Żychlin are of the highest quality and meet all, even the most strongest requirements of the Customer. Also in the area of Customer service, there is no place for compromise, and therefore, among the fundamental objectives of the company is, inter alia, the constant
Manufacturing-Journal | 63 |
improvement of the quality of business activity. In order to effectively realize the aspirations set out above, it is necessary to conduct a series of actions and investments in different areas of interest of the organization: HR, infrastructure (machines and specialist equipment), the optimization of procedures of production management, logistics, etc. That’s why Fabryka Transformatorów in Żychlin Sp. z o.o. introduced the Integrated Quality, Environmental and Safety Management System, and constantly strives to improve the qualifications of its Employees, regardless of
is attached today to the issue of environmental protection, to minimize the negative impact of business activity on the environment. Any company wishing to expand must meet these requirements, and to preserve the value of public image and maintain and improve its competitive position. Integrated Environmental Management System in Fabryka Transformatorów in Żychlin implies, inter alia, compliance with legal and other requirements regarding environmental protection, and prevent the emission of pollutants into the environment. Naturally, special certificates owned by the
position. Implementation of the wellconducted trainings, tailored to the specific competency requirements for a particular position means that both the Employees who have the opportunity to develop hard and soft skills, as well as the company’s Customers are satisfied. Except high quality products offered by Fabryka Transformatorów, a wide selection also matters. Still broadened company’s offer guarantees that everyone will be satisfied. The company manufactures all major types of transformers, including power, distribution, dry-type, arc-suppressing and furnace transformers, as well as reactors. Naturally, the detailed specifications of ordered products are fully modified, depending on Customer demand.
company, guard the quality of products situation and current economic ideoloffered by the organization. These certif- ogy in Poland, was able to flourish and icates (PN-EN ISO 9001, PN-EN ISO 14001 maintain a strong, competitive position, and PN-N 18001) guarantee that the even among its rivals from the West, at company maintains the most strongest the same time investing heavily in the standards for environmental protection, emerging, modern technologies. human health and safety regulations and implementing optimal procedures Written by Jacek Głowacki in the field of production management. Thanks to those efforts undertaken We produce copper and aluminium conductors and wires by the company, each customer can Bare and insulated be assured that the Shaped product he ordered Round Trolley wires not only isn’t worse Bus bars than transformers Commutator bars manufactured in Western Europe, Fabryka Przewodów but also is proEnergetycznych S.A. duced in order to ul. Sielecka 1, 42 - 500 Będzin Tel. +48 (32) 267 30 41, 761 63 01 maintain the deliFax. +48 (32) 267 77 49, 761 63 05 cate ecological bale-mail: fpeinfo@fpe.com.pl www.fpe.com.pl ance. It is proven
Ecology and professionalism
Customer requirements are growing nowadays, business awareness is also changing, and much greater importance
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by the fact that some products are sold abroad and among the company’s Customers, we can find dozens of Polish and foreign organizations operating in the energy sector, including the largest suppliers of electricity in our country.
Summary
The history of Fabryka Transformatorów in Żychlin Sp. z o.o. is a beautiful, and true, tale, telling how a company, which for ninety years worked hard to develop Polish engineering industry, not only did not waste its huge potential and rich experience, but, whatever the political
ARTICLES |
Consumer GoodsSaint-Gobain
A global leader among glass manufacturers
F
rom the moment when, as the legend says, a few thousand years ago, couple of Phoenicians – the representatives of the nation of fearless sailors and merchants – accidentally created first, irregular and poor quality items made of glass in a campfire, this new material fascinated man. Regardless of geographic region, cultural group, level of the advancement of civilization, all men lusted cups, mirrors, other objects and pieces of art made of glass – purchasing glass objects indicated a high social status and wealth of the owner and the secret of producing high quality glass was carefully guarded, since profits from the sale were simply fabulous. Today, when the technology of glass production is no longer a mystery, this material has already lost its magical charm, yet we still feel pleasure when we are surrounded by delicate and fragile glass, so often used in interiors design., Fortunately there are still companies that continue the tradition of manufacturing top quality glass, which, in addition to its basic functions, enjoy us with the originality of execution: design, colours, and ornaments. One such company that has gained a well – deserved reputation of a global leader among glass manufacturers, is Saint-Gobain Glass, and a jewel in the Group’s crown appears to be the Polish company of the organization – SaintGobain Glass Polska Sp. z o.o., with main office in Dąbrowa Górnicza.
ally became the owner of the facility in 2003. “Over three hundred years of tradition in glass production and processing, huge experience, knowledge and know – how of a world leading producer offered new development opportunities to our Polish company” – says Mr. Hugues Denissel. Of course, such statement is not surprising if we realize the fact that Saint-Gobain Glass is a company, which is the world’s second largest glass manufacturer, founded in the first half of the seventeenth century in France, to break the domination of the Venetian manufacturers. The decision to
FACT BOX
The History of the Company
Saint-Gobain Glass Polska owns three plants in our country: in Dąbrowa Górnicza, Wałbrzych and Jaroszowiec. “Jaroszowiec Glasswork’s history is a positive example of successive transformations in Polish economy” – explains Mr. Hugues Denissel, CEO of Saint-Gobain Glass Polska, who showed us the secrets of activity of the factory in Jaroszowiec – an important link in the development strategy of the company in Poland. Jaroszowiec Glassworks was founded already in the early 60s. After the fall of communism, many companies, without state support, were on the edge of bankruptcy. In the new conditions, only the best managed to survive – including the establishment in Jaroszowiec. Excellent results of the factory’s activity and its dynamic development, drew the attention of the authorities of SaintGobain Glass. The company eventu-
FULL NAME: Saint-Gobain Glass Polska Sp. z o.o. oddział Jaroszowiec CEO: Hugues Denissel PLANT DIRECTOR: Michał Pietruszewski OPERATIONS: Decorative glass production ESTABLISHED: 1961 (joined to SG 2003) EMPLOYEES: 270
www.saint-gobain-glass.com Manufacturing-Journal | 65 |
purchase Jaroszowiec Glassworks was accurate. Its direct consequence was another investment: in 2008 the company bought the glass factory in Wałbrzych, which allowed the company to increase decorative glass production capacity by 50%. Nowadays, the Jaroszowiec Plant is known at the domestic and international market as a producer of ornamented glass manufactured by continuous process. High glass quality and attractive offer allows this type of glass to be used in many different applications. The main ones include: furniture, interior decoration, windows and solar” – concludes Mr. Hugues Denissel.
The Pillars of Success
Every organization, which has been and still is successful in a particular area of business activity, has the ability to optimize all key elements of the company’s activity. Saint-Gobain Glass Poland is no exception to this rule, as we find out after analyzing the company’s actions, using Jaroszowiec Glassworks as an example. The factory maintains the position of very important facility owned by the company in Poland. Human Resources managing methods are a must for any business who wants to be successful at the long term. Years of experience in the implementation of HR procedures in Saint-Gobain Glass, result in a modern and effective personnel policy in the Jaroszowiec Glassworks. Let us listen to Mr. Hugues Denissel: “We hire our Employees for the long term, and they develop throughout their careers with our company.” Hard skills are but not everything.
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Saint-Gobain Glass’s managers believe that creating an excellent atmosphere in the organization, is equally important issue, which affects the quality of work: “In our company we promote dialogue and communication. (…) One of the many Saint-Gobain Group’s conducts and principles is respect for others, which is obligatory rule for all Employees. I think that good atmosphere at work results from a clear definition of the objectives, good work organization and also mutual support of supervisors and Co-workers” – summarizes Mr. Hugues Denissel. However, even perfectly prepared for their tasks Employees wouldn’t be able to do much without appropriate technological support. Jaroszowiec Glassworks can be proud of its machine park. As Plant Director of Jaroszowiec Mr. Michał Pietruszewski says: “Today, production technology used by Jaroszowiec is at the highest level on the market.” Behind the investments, aimed at upgrading the company’s technology, stand enormous experience and know – how of Saint-Gobain Glass. For this reason Jaroszowiec Glassworks has already in 2007 implemented the 5S system (sorting, straightening, systematic cleaning, standardizing, and sustaining the discipline), effectively organizing the company’s work environment. “Since we also introduced Lean Manufacturing rules, which make our actions to be developed continuously and increase the commitment of Employees.” – adds CEO, Mr. Hugues Denissel. Due to these activities, Saint-Gobain Glass has gained the trust of Customers worldwide, offering a wide range of glass
products, which thanks to the highest quality workmanship and differentiated design satisfy every customer, regardless of taste and the specificity of the contract. “We obey market signals very carefully and we follow world – wide trends to create new products that are well received by our Clients” - says Mr. Hugues Denissel. It is worth noting that the company’s products are divided into two types: SSG Albarino for solar market and SGG Decorglass for interior design applications. “Moreover, we recently introduced in our plant of Jaroszowiec the exclusive Masterglass range. Its geometrical and modern design is an international success that boosts our export towards Western countries” – claims Mr. Denissel. Saint-Gobain Glass Polska provides products made in Polish plants to most countries in Europe, and as many as 2/3 of decorative glass production travels abroad. Naturally, prestigious certificates guard the highest quality of products manufactured in Jaroszowiec and other glassworks. “We hold an integrated management system of quality and environment ISO 9001 and ISO 14001, which enables us to realize production in environment friendly conditions” – lists Mr. Denissel. The ecological
aspect of the company’s activity occupies a very important role in the development plans of the organization. As a proof, Jaroszowiec in complement to its decorative range is offering the first “lead-free” mirrors produced in Poland, in which the lead content is 600 times lower than the specification. The direction of the development of the company, coupled with its experience and its Employees’ skills, guarantee the period of dynamic growth, undoubtedly ahead of Saint-Gobain Glass Polska in the coming years. Written by Jacek Głowacki
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ARTICLES |
Automotive IndustryIsuzu Motors Poland
Engines of the Industry
T
here are only few drivers who know what engines their cars are fitted with. This knowledge is vital, however, and Isuzu Motors Poland’s (Ispol) success story will tell you why. This automotive subsidiary can hardly be outshined by any of its business partners. The facts speak for themselves. Launched by Mr Leszek Balcerowicz himself, the plant has turned out more than 2 million engines for the industry tycoons such as Opel/Vauxhall, Honda and Mercruiser.
Prime the Pump
President - Fumio Morinaga
Vice President for Production - Paul Staes
FACT BOX
FULL NAME: ISUZU MOTORS POLSKA SP. Z O.O. PRESIDENT: Fumio Morinaga OPERATIONS: Automotive ESTABLISHED: 1997 EMPLOYEES: 715 - at the end of April 2011 TURNOVER: about 1,5 MLD PLN (2010)
www.isuzu.co.jp
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Isuzu Motor Poland’s success story began more than 14 years ago, in January 1997. Having consulted several different locations with General Motors, the Japanese investors eventually came up with the idea to create new jobs in Tychy, in the Katowice Special Economic Zone. “Economic zones offer preferential conditions for those who run their businesses there. Thanks to this, we have benefited from several government grants, including income tax exemptions and property tax reliefs. The money we saved has been put into a new factory. We have designated a lump sum of over 2.5 billion yens (ca 193 million USD) to develop it,” says Ispol’s President, Mr Fumio Morinaga. With its foundation stone being laid in May1997, the plant, even under construction, began to attract attention of businessmen and politicians alike, including Mr Lech Wałęsa. Finally, the serial production of 1.7 Diesel engines was launched on 14th June 1999. This had been preceded by the visit of GM Corporation’s President, Mr Rick Wagoner; and the tree planting action run by the company’s first Presidents, Messrs Hisaomi Sasaki and Hiromu Inada. The first Japanese invest-
ment on this scale in Poland required suitable celebration. The factory’s grand opening ceremony gathered more than 500 prominent figures, including Poland high government officials, General Motors top executives and artists recognised both in Poland and Silesia. Among the guests were Mr Leszek Balcerowicz, Poland’s Deputy Prime Minister, and Mr Arvin F. Mueller, GM Vice President and Powertrain Group Executive. Messrs Ryszard Kalisz, Kazimierz Kutz and Andrzej Wajda were also invited.
Joint Venture with GM
It was hardly accidental, of course, that GM representatives attended the ceremony. A few years back the Isuzu 1.7 engines catered for Honda Civic (first Honda’s Diesel engine was made in Tychy); a limited number of these units also drove Mercury Mercruiser luxury motor boats. At present, however, the factory works exclusively for Opel/Vauxhall, supplying the engines to a variety of passenger vehicles, be it Corsa, Meriva, Combo, Astra or Zafira. In 2002, General Motors bought 60 % of Ispol’s shares. Since the joint venture between Isuzu and GM, the Tychy plant has been working hand
changed and so have the engine head and the injection system. In a word, almost everything is different now. In all honesty, there is no single 1.7 Diesel engine that we can talk about, but a whole family instead, with the capacity as their common denominator. All these engines vary in terms of the amount of labour and production time they require. Our Flexible Cell System makes it possible for us to balance all this out and to facilitate the production process,” emphasises Ispol’s Vice President, Mr Paul Staes. in glove with Opel/Vauxhall factories. Fitted with the Tychy-manufactured Diesel engines, these cars are marked by low fuel consumption. Reliable, efficient and environmentally friendly, these units make one of the best Diesel motors manufactured worldwide. A few groundbreaking events will testify to this. The millionth Diesel engine left the factory on 11th May 2004; 2 years later the business launched the new generation NCL unit. In 2009, the factory commemorated the engine no. 2,000,000 being produced. “This remarkable result, which coincided with the plant’s 10th anniversary, would have been hardly possible if it had not been for our workers. It is thanks to their commitment that we could launch our state-of- the-art D1 engine, too,” remarks Mr Morinaga. In addition, Ispol’s position on the market is well reflected by a number of prestigious awards and quality certificates.
Beyond Recognition
Ispol is distinguished by its capability to produce high-performance, high-qual-
ity, low-cost engines with minimized impact on the environment. The business looks to its laurels, however, and environmentally friendly solutions call for equally environmentally friendly methods of production. For this reason, the plant conforms to the EC’s strict environmental regulations for noise, drainage and soil pollution. The plant also incorporates cutting-edge production technology such as the Isuzu Flexible Cell system, which enables production volume or engine types to be adjusted flexibly. “But for capacity, Isuzu Diesel
engines have changed beyond recognition since the 90s. The crankshaft has
Step by Step
What are the stages of the process? As soon as the pistons are placed into the cylinders, the engine blocks are wrapped up carefully and shipped from Japan to Silesia. On its arrival, the undressed cast is machined into the engine head, which is followed by the complete assembly of the engine, together with its fittings. Wherever there is need for ultimate precision, the plant incorporates automated labour. Nevertheless, since human labour makes it possible for the business to adjust the volume of production to the actual market demand, the vast majority of assembly work is performed manually. Should the quality suffer at the hands of the workers, the Japanese production and quality control system comes into play. The feather in the company’s cap and a unique engine diagnostic tool is the hot-test,. This is how it works. Every new engine is mounted on a special platform and it is on this platform that the engine enters the diagnostic chamber. The engine is started there and undergoes a test that indicates any potential failure. Remarkably enough, Ispol is counted among the few engine manufacturers that use this procedure to test 100 % of their output. Consequently, the risk of the engine failure has been reduced to a minimum. “A reliable engine means a satisfied Customer. Quality is our ultimate goal. However, it has to be combined with affordable pricing and timely delivery, too. Only then will our Clients be fully satisfied with the product,” says Mr Staes.
Young Gems, Bright Future
Quality, Cost and Ddelivery are but a means to an end. „Our mission? We implement our QCD policy in order to produce the best engines in Europe. We
Manufacturing-Journal | 69 |
do our best to involve our workers in the process, too,” replies Mr Staes. With its generating capacity of more than 330.000 motors a year (when working on three shifts), the company gives jobs to 760 workers at the moment (over 500 people employed directly; another 200 hired by employment agencies; all these working on two shifts). Massive production calls for the best staff there is. Hence the idea to provide technical training in Japan itself. “The first session we organised took place in 1998, before the launch of the factory. We organised yet another training in 2006. More than 120 members of our staff flew to Japan to spend 3 months at the original Isuzu production lines,” adds Ispol’s HR Manager, Artur Kluba. For a number of years Ispol has been subsidising its staff in terms of their education, be it secondary school (for adult students) or university studies, both undergraduate and postgraduate. It is of their own accord that the staff can embark upon the programme. The only condition is
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that the programme and level of study have to match the workers’ position in the company and their field of expertise. The business provides for 100 % of their tuition fees, from the beginning of the second semester to the end of study, and the figures involved reach 20,000 PLN per worker. More than 200 people have benefited from these subsidies so far (the majority of them took up either Bachelor’s or Master’s programmes). Ispol’s talent management scheme also deserves the credit. The workers shortlisted for the scheme can follow individual paths of their career and benefit from various forms of vocational training. “This scheme helps us raise the staff that is both young and professional. We spare no expense on its language courses, either. In the multinational and multicultural environment like ours, effective communication is a must. We do our best to make it as smooth as possible,” summarises Mr Kluba.
Shape of Things to Come “We have already left the crisis behind us. Polish economy is gaining momentum now and this has already given quite a boost to the automotive industry. Poles are growing richer. With the popularity of second hand cars in decline, the sales figures of new vehicles are rising rapidly. This is a real chance for us and we are not going to waste it,” recaps Mr Staes. The figures speak for themselves. Last
year the volume of production and the rate of employment soared by 34 % and 12.5 % respectively. With profits on the increase and new people onboard, the future looks promising for Isuzu Motors Poland. Written by Bartosz Sowiński
ARTICLES |
Automotive IndustryWezi-tec
Better - faster - innovative
W
e live in wonderful times. Speaking of the Golden Age in the context of the fastest development of science and technology, we think often of the Renaissance era, the decades, when such masters as Leonardo da Vinci, Giorgio Vasari and Erasmus of Rotterdam were creating their immortal works. The power of the Renaissance thinkers manifested itself primarily in new mentality, the strength of ideas that revolutionized the old, replacing it with an innovative approach to the problem of human nature, truth and beauty. The original way of thinking about the world, discovered by the visionaries centuries ago, is easiest to characterized by the statement that the only thing hindering the potential of creativity of the pioneers of modern Western civilization, are the borders of imagination. But if we look at today’s pace of development of cutting-edge technologies, we will quickly come to a conclusion that the Golden Age of humanity is happening right now, new inventions and solutions using the latest achievements of the human mind appear in our lives virtually every day. At the same time, we have never before accomplished, as societies, such a high level of business and technological awareness, we were not so emphatic in relation to the world around us, we did not understand the process of decision – making, primarily motivated by the concern for the environment. Today, it is different, we are other, better people in other, better times. New times and new people are in need of new methods of management and manufacturing, taking into account the changes taking place in ourselves. Just like a few centuries ago, we build factories – factories of ideas. One of such companies, which sets the trends, already flowing from the new philosophy of life, is Wezi-tec Sp. z o.o. from Legnica. The beginning of a revolution in the activity of enterprises Wezi-tec Sp. z o.o. is a young, attractive and full of enthusiasm daughter – company of WEBER GmbH & Co., whose history dates back to 1949, when Josef Weber founded a small company manufacturing mineral lutes for stoves and heating boilers. Many years later, renown and globally recognized organization decided to establish a Polish branch. This is how Wezi-tec Sp. z o.o. based in Legnica, Lower Silesia - one of the most dynamically developing regions in our country, was founded. The opening of the facility was cited in 2003 and the production started just a year later. The company’s professionalism and capabilities are demonstrated by the fact that within only four years of the organization’s activity, it has made tremendous progress, employment has grown significantly and the company expanded its infrastructure, effectively responding to the increasing production needs. An important milestone in the history of the company was opening a high – tech painting station, which allowed the company not only to significantly expand the scope of services offered by the organization, but also to reduce the cost of activity, which in turn increased the investment opportunities of fast – growing organization. At the moment, Wezi-tec Sp. z o.o. is one of the most important pillars of WEBER Group, manufacturing plastic components, various models and sys-
tems, and cooperating with giant companies, recognized around the world, who represent many industries, from automotive sector, through manufactures of household appliances, to producers of advanced equipment used in heating technique. The turnover of the company reached 13 million Euro in 2008.
FACT BOX
FULL NAME: Wezi-tec Sp. z o.o. PRESIDENT: Dr. Thomas Zipp OPERATIONS: Automotive ESTABLISHED: 2004 EMPLOYEES: 300 TURNOVER: 22 360 000,00 Eur
www.wezi-tec.pl Manufacturing-Journal | 71 |
Visionaries in the service of innovative solutions The organization that has the ambition to implement the cutting – edge solutions in the area of technological investment, management methods, production processes and wants to build a corporate image based on contemporary values, hast to create a team of Employees who understand and sought to act in accordance with the philosophy, which goes far beyond mediocrity. For this reason, the accurate HR policy in Wezi-tec Sp. z o.o. is a priority. At this point, the company hires over 300 Employees. The organization runs a large
– scale operation aimed at sustainable development of staff skills, both soft and hard, which significantly affects not only the ever – higher quality of products offered by Wezi-tec Sp. z o.o. but also means that the company is viewed simply as an attractive employer, caring about its Employees. Trainings are a essential part of HR policy of any modern company. Wezi-tec is no exception. The strategy of the company involves seeking to operate in a dynamic and flexible way in every situation to ensure achieving the first priority of the company – Customer satisfaction. By hiring a team of Employees, perfectly prepared for their tasks, the company should also create an optimal organizational struc-
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ture. The basis for the success of Wezitec Sp. z o.o. is fast decision-making process, due to the effective allocation of competences. Flat hierarchy, a wide range of personal responsibility and autonomy of each Employee, attaching great importance to the issue of direct communication makes that no project is impossible to accomplish. Individual approach to every order and full cooperation with the Customer at every stage of production process make Wezi-tec a trustworthy organization, as evidenced by the references from the strategic business partners, like Audi, Daimler, Eugen Wexler, BMW, Dräxlmaier, Faurecia, Johnson Controls, Key Plastics, Skoda and Volkswagen. Naturally, for such a recognized manufacturing companies, what matters is the highest quality of offered products, hence strict requirements for suppliers. Wezi-tec Sp. z o.o. is a leader when it comes to standards of performance of all elements of the company’s product offer. The production area exceeding 10,000 square meters, modern machinery and optimized methods of production, combined with the philosophy of radical elimination of waste, assure the highest quality of all components, adjusted to Customers’ requirements. All this is possible thanks to many years of experience and support of WEBER Group – a pioneer in the implementation of modern solutions in the production process. Wezi-tec operates according to WEBER’s motto, which is “Best in Class”. The company from Legnica offers a full set of pre– and post–production services, such as conceptual design, manufacturing of tools and testing. The company’s products are characterized by such features, as functionality, durability and safety. Wezi-tec gives shape to ideas. Of course, it is difficult to expect that such a reputable organization like Wezi-tec Sp. z o.o. did not have the prestigious certificates, ensuring compliance with the most stringent standards of quality. Wezi-tec boasts such documents, as DIN ISO 9001:2000 and ISO TS 16949:2002.
organizations is entering a new level. Wezi-tec Sp. z o.o. uses only environmentally friendly materials, to minimize the amount of waste generated in the production process. The company understands the need for careful handling of limited resources. We only have one Earth, let us remember. Supporting initiatives of local communities, taking care of Employees, listening to their needs and meeting them: these are actions taken by the company, which wants to build a real, not a mathematical value of the company. The scope of Wezi-tec’s activities is broad and includes, inter alia, funding sports activities of Employees and organizing integration meeting, deepening friendly relations within the team. Wezi-tec is a beneficiary of many years of experience of its German owner, Weber, which has been repeatedly praised by customers and external organizations for achievements in the field of innovation, implementation of the latest technologies and highest quality products. The number of awards earned by the organization is very high and includes an award granted by Audi for the best quality products, numerous awards at Plastics Fair in Düsseldorf in the field of technical parts and even SPE – Management Award for the best homepage. Wezi-tec Sp. z o.o. is also an Oscar finalist in the Mittelstand class, The Author of the Tool of the Year and winner of the Best Factory Award. An example to follow, Wezi-tec Sp. z o.o. proves that we can watch the real Golden Age of science and technology right here, right now. Written by Jacek Głowacki
“Tomorrow is today – but tomorrow”
This maxim, written by Sławomir Mrożek, one of the most famous Polish dramatists, perfectly fits Wezi-tec’s philosophy. Today, better than ever before, we understand the need for work for the generations coming after us. For this reason, the business awareness of many
Manufacturing-Journal | 73 |
ARTICLES |
Automotive IndustryGT Poland
Professionalism for the customer
O
perating in the area of the automotive industry, the Polish branch of the Italian group Gammastamp concedes particular importance to the quality of the relation with its customers, professionalism, and the well-being of its employees.
The beginnings in Poland
General Director Maurizio Scaglia
FACT BOX
FULL NAME: GT Poland Sp. z o.o. PRESIDENT: Maurizio Scaglia OPERATIONS: Automotive ESTABLISHED: 1996 EMPLOYEES: 280 TURNOVER: 120.000.000 PLN
www.gtpoland.pl
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GT Poland Ltd., with its seat in Skoczów, forms part of an international group called Gammastamp, which has been a real leader in the production of automotive parts and components for 50 years, introducing innovative technical and technological solutions. Other companies belonging to the Gammastamp Group include: Gammastamp SpA, GT do Brasil, GT Tooling and Tecno V SpA. They operate in a manner which is integrated with regard to the strategies, objectives and the methods of production. Gammastamp entered the Polish market following Fiat; at the time when Fiat Auto Poland was established, the Italian company also opened its branch in Poland. At the beginning, GT Poland, started on April 1st, 1996, operated as a supplier for Fiat Auto Poland, delivering
such components as lateral door hinges, handbrake levers, etc. Increasing the assortment of products resulted in building a new production plant in Pierściec, not faraway from Skoczów. Accordingly, the number of people employed in the company raised from ca. 150 to ca. 300.
The successful strategy
Among the customers of GT Poland Ltd., one can include Fiat Auto Poland, TRW, Autoliv, KSS, the companies which make up the Gammastamp Group and other subjects operating in the automotive industry both within the Polish and the international market, thus world-wide, with their plants located in the North and South America, Asia (in particular, China), the Far East, and of course in Europe. The key factor contributing to the
Manufacturing
Journal
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Manufacturing-Journal | 75 |
success and prosperity of the company consists in its care about the customer, and so in taking into consideration, as much as it is possible, all his requirements. It also consists in the effort to spare the customer any problems or inconveniences which might relate either to the quality of products, or to logistics. For, as emphasized by Maurizio Scaglia, the CEO of GT Poland Ltd., only the company which does not put the customer to inconvenience, has the right to exist on the market. Besides this, an additional advantage, on the part of the enterprise, amounts to its flexibility – the ability to respond in the positive to specific requirements and needs of the customer. Treating the customer with respect and attention, paid on all the levels of its organization: from machine operators to office workers, the company wins trust and recognition as a professional supplier.
Developing projects, technologies and production
The research and development activities are performed mainly in Italy, and so the product commercialized by GT Poland Ltd. cannot be regarded as entirely its own product. The range of projects carried out by the enterprise, however, encompasses technologies and methods of production aimed at developing cer-
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tain kinds of facilities and equipment. In other words, even though the orders of the customers are carried out on the basis of projects developed in Italy, the details of the execution are decided upon by GT Poland. Thus, for instance, recently the company has developed a new galvanic line, a technology which involves the use of nickel-chromium alloys. Obviously, this only forms part of a wide gamut of processes developed by the companies which belong to the Gammastamp Group. With the use of highly advanced technologies and innovative solutions, building on excellent organization, Gammastamp, and accordingly GT Poland, operates such processes as fine blanking, progressive stamping, galvanizing, overmoulding, welding and assembly of particular parts and components for the automotive market.
Caring about the quality of products and about the environment GT Poland Ltd. has been granted quality certificates which confirm that it observes the norms in line with the ISO TS system and with the ISO 14001 environmental management system. Furthermore, there are specific prescriptions which determine ways of conduct in a variety of processes, such as production, design, ordering, or equipment maintenance. Once a year the conformity of the quality system, applied by the company, with the set standards (the above mentioned ISO TS and ISO 14001) becomes
verified by an external agent. The environmental management system makes it obligatory for the enterprise to actively care about the environment. In practice, this amounts to the reduction of the consumption of resources, such as electricity, heating, water etc.; as well as to cutting down on the emission of gasses and pollutions. In particular, the galvanic waste water is treated in a closed circuit in one of the company premises. Also, the company has implemented a programme aimed at minimizing the amount of communal and industrial waste, and at preventing the release of harmful substances into the environment.
Creating a friendly work environment
It goes without saying that every company can build its success predominantly on the following two factors: paying due attention to the requirements of the customer and the appropriate HR policy. For, one should admit, it is the people who work for a company that constitute its basic resources. While taking this into account, GT Poland ensures not only periodic evaluations of its employees, but also, depending on their current needs, a system of courses intended at instruction and the improvement of knowledge and skills of the employees. These courses are organized either by an external institution or by the company itself and, in most cases, they are strictly related to the activities which the employees are obliged to take up as part of their work, making them better acquainted with new methods and technologies. It is one of the principal aims of the company that the persons employed in it work well and be satisfied with their work, fully aware of their tasks, capacities, and performance. Mr Scaglia stress-
es that those who are discontented with their work usually perform not as well as those who are highly motivated, involved and interested in what they do. Therefore, making for a friendly work environment indeed contributes to the better fulfillment of the company’s own objectives. Meetings held on a weekly basis in order to discuss current matters pertaining to the enterprise’s current interest serve the purpose very well. It is worth mentioning that GT Poland Ltd. possesses its own social fund from which to cover additional expenses, such as the costs of treatment, in the event of a serious illness or any other emergency which might befall an employee. These financial resources are also spent on organizing holiday programmes for the children of the employees.
Plans for the future
The Gammastamp Group offers products which have gained appreciation and recognition on the market of the automotive equipment including, e.g., first installation components (hinges, door checks, handbrake levers etc.), seat belts and other door lock components, and so forth. In particular, GT Poland Ltd. specializes in the supply of parts which are related to the safety of passengers, such as fasten-
ing elements in seat belts. In the future – as Maurizio Scaglia points out – the company intends to strengthen its position on the market, which means that it is going to meet the demands of its existing customers but also to win new customers, for the products, developed thus far, with their established market position. It will focus, therefore, on the development of these products and technologies, the more that they require the use of sophisticated equipment, and this entails high expenditures.
Things to take pride in
The achievements which the company’s CEO regards as particularly significant and seems to value most come down to the following two facts. First of all, it is the fact that persons who work for the enterprise are really involved in their tasks. In this way, they consider themselves as parts of a whole, realizing that all their successes, and failures (if there are any), should be attributed to and shared together by the whole team. The high degree of conscientiousness of the employees, true interest and involvement altogether make for the common welfare of the company and satisfaction of its customers with the products and services which it offers. Secondly, it should be emphasized that, as a matter of fact, all of the customers are satisfied with the activity of GT Poland Ltd. and with their collaboration with the company, which is manifest in their good evaluations of it. And, last but not least, the satisfaction of the customers is directly reflected in the satisfaction of the company with the results which it achieves. Written by Anna Tomaszewska
Manufacturing-Journal | 77 |
ARTICLES |
Automotive IndustrySitech
An expert among professionals
M
odern business management books put emphasis mainly on the dynamics of growth of the organization. They say that the company develops only when its competitive position continues to strengthen, and the company itself carries on actions oriented on continuous expansion in all fields. The main aim of the company is to achieve total recognition among Customers and to dominate the market as much as it is allowed by the local antitrust regulations. From the university dissertations, full of graphs, tables and econometric models, one can learn that in order to enter the path of rapid growth. The organization must properly invest its capital, make accurate decisions, build its value on many levels, not to focus only on the balance of profit and loss... Everything that I wrote above, is undoubtedly true. But the years of business experience prove that there exist companies that are crucial to the existence of the greatest global giants. I am thinking about expert organizations: highly specialized, the most trusted suppliers, jealously observed by competitors, organizations that gather professionals and enthusiasts, fascinated for years by their contribution to chain of values created for the Customer. I am thinking about Sitech Sp. z o.o.
The History of the Company
Sitech Sp. z o.o. was established in 1998 as a joint venture company with Volkswagen AG and KWD. Production based in a modern factory in Polkowice, in the Lower Silesia region, started just a year later. The choice of location was not accidental of course. Polkowice is one of the most attractive, in terms of investment, counties in Poland, attracting major international manufacturing and service companies. The LSSE subzone – one of the most inviting business zones in Poland – is also located in Polkowice. Placed a few dozen kilometers from Wrocław, the city cares for maintaining extensive infrastructure in excellent condition. Polkowice is also placed by the popular transport route, which makes the optimization of logistics processes much easier. Due to these factors, Sitech Sp. z o. o. was able to develop freely. Just a year later the company’s staff could celebrate exceeding the limit of 1 million manufactured PQ35 car seats. In 2008, the company celebrated a decade of activity. On this occasion, the company’s authorities made a decision to significantly expand the R&D department. In 2009, thanks to a grant, obtained by the organization from the European Union under the 4.1 Innovative Economy Programme, Sitech began production of a new model of modular seat, which is used in several models of
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cars within Volkswagen Group. At the moment, Sitech Sp. z o.o. is a renown strategic partner of the German company, producing highest quality car seats.
FACT BOX
FULL NAME: Sitech sp. z o.o. PRESIDENT: Hans - Joachim Schreiner OPERATIONS: Automotive ESTABLISHED: 1998 EMPLOYEES: 1680 TURNOVER: 250 mln euro (2011)
www.sitech.com.pl
The Pillars of Success
As i have already mentioned, Sitech is a specialized organization, respected and trusted by its Customers. From expert organizations, precisely because of their clearly defined scope of activities and the need to acquire only the best professionals in the industry, is expected much more than from other companies. If we analyze the solutions used in different aspects of the company’s activity, we will see, how wide is the range of the activities of the organization and how important they are to achieve success. In every organization in the world, its Employees are the most important elements of the company’s strategic potential. In Sitech we can see that even more than anywhere else. The company employs exactly 1680, perfectly prepared for their tasks, Employees. The scope of business activities in the area of HR policy is very extensive. The organization puts great emphasis on proper communication among the teammates, assuming that generally understood dialogue is the basis for solving problems and preventing them. To achieve this
objective, the company uses a lot of tools, for example an annual survey, called “mood barometer”, thanks to which Employees themselves identify areas of communication, which they think should be improved. The rich benefits package, which includes, inter alia, free medical care, social events, financial and organizational support of the Employees’ initiatives, funding for the Employees’ sports and cultural activities and many others: all these factors build Sitech’s reputation of an excellent employer. If we add conducting ongoing training and development programs, and even subsidizing education of the Employees and maintaining close contacts with universities in the region, we will have a whole picture. Sitech operates in a very specific business environment. The most important Customer of the company is the Volkswagen Group, which is at the same time the company’s owner. The result of such a situation is that on the one hand, the organization maintainins an excellent position of one of the most important, strategic partners of the international giant, but on the other hand, in the face of rapidly
Manufacturing-Journal | 79 |
growing competitors, who dream to take Sitech’s place, the company must always be ahead of its competition. For this reason Sitech Sp. z o. o. attaches so much importance to the issue of technological superiority. Due to the efforts of creative R&D department, the company’s engineers were able to start the production of a module car seat, which a number of cars produced in the Volkswagen Group’s is equipped with. MS model is implemented in the Audi A8, A7, A6, A5, Audi A4, Audi Q5 i VW Passat, while PQ35 model can be found in the VW Golf VI and VW Touran. Comfortable and safe, module car seats high-tech, future solution, and the greatest source of pride for Sitech’s Employees. Professionalism, excellent preparation, both theoretical and practical, and the commitment of the company’s Employees, are still not everything, what needs to be ensured, to achieve success by a company, which carries on its business activity in a very demanding, automotive industry. To achieve the company’s objective, which is to maintain consistently high quality of manufactured products and ensure Customer satisfaction, an appropriate technology is also necessary. Due to accurate investment decisions, the factory in Polkowice is one of the most modern production plants in Poland. The R&D department mentioned earlier, is also well equipped and capable of taking up another challenges in the area of development and improvement of technologies used by Sitech Sp. z o.o. Thanks to close cooperation with Volkswagen, the company may benefit
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from the unprecedented experience of the German organization, especially in the issue of solutions, which main task is to optimize business processes. We consider both the production processes, as well as those related to logistics management or HR policy in the company. Such cooperation brings great results, as evidenced by the award granted to Sitech Sp. z o.o. in the competition of the Polish Logistics Association 2010 for the adoption and implementation of the project: “Optimizing supply chain by developing an innovative coordination of shipments”. To maintain a strong competitive position, it is also necessary to keep a watchful eye on industry changes. The main proof of exceptionally strong position of Sitech Sp. z o.o. in automotive industry, is the “Moto Trendy 2011” award, granted for setting high standards of work. The chapter of this prestigious award, especially appreciated the dynamic development of the company. Sitech Sp. z o. o. is well aware of the need to participate in the process of formation and development of the industry. Therefore, the company’s representatives participate in international conferences, and industry events. The company’s priority is a satisfied Customer, so Sitech Sp. z o.o. strives to make sure that its products meet the most strongest quality standards. Because of that, Sitech works exclusively with trusted suppliers and is constantly expanding and improving its existing product range. A globally recognized company, such as Volkswagen, attaches great
importance to the issue of selection of cooperators. The Group’s suppliers must meet the highest requirements in terms of quality of delivered products and professional approach to their work. Sitech’s position among the German company’s partners is best described the strategy adopted by Volkswagen. It says that “drive starts from the seat”. Car seat is the first and one of the most important elements that are to bring the full satisfaction of the Customer and make Him feel really comfortable, driving one of the cars, manufactured by the company. This strategy makes the company from Polkowice one of those partners, who have to meet the most strict requirements. Meanwhile, Sitech Sp. z o.o. continues to carry on its tasks perfectly for years, manufacturing the highest quality seats. Nowadays, it is crucial to build the value of the organization in every context. Particularly important is the company’s activity in the field of ecology and CSR. Sitech Sp. z o.o. has something to be proud of also in this aspect. The company carries out actions aimed at reducing energy consumption, according to the Group’s idea: “think blue”. Innovative, dynamic, professional: these are the three words that best describe Sitech Sp. z o.o. With a fully professional approach to the issue of cooperation with Volkswagen - the owner of the company and maintaining the highest standards of quality products, we can be sure that Sitech’s future seems to appear bright and full of successful moments.. Written by Jacek Głowacki