Manufacturing Volume 2/5 - 2010
.
â‚Ź5
The World of Business
Journal
magazine
The most ecological brand in europe
page 37
The Polish GEM of GM
page 12
Scania buses from Poland ...
page 16
Księga1.indb 1
2010-04-28 14:52:11
Księga1.indb 2
2010-04-28 14:52:15
EL UD E PR
Dear Readers!
T
he global economy and the impact of financial crisis, as well as the strengthening of environmental protection concepts require further automobile manufacturers to develop new technologies to develop new energy-saving emission reduction models , green new energy auto market is a vibrant and future markets. While the financial crisis still exist, but this year’s automotive market has begun to rise again, the world’s major car brands have come to well-known exhibitors. In this issue we encourage you to read the articles about leading companies from the automotive industry, domestic appliances, food & beverage. With global headquarters in Detroit, General Motors has its manufacturing operations in 34 countries, including a Polish factory in Gliwice (General Motors Manufacturing Poland). Specializing in the Opel cars production, it is one of the most modern plants of General Motors in the world. Company’s Achievements are told by Mr. Antonio Francavilla General Manager GMMP. Magneti Marelli is a leader on international market of design and production of components and high-tech systems for automotive industry. The group offers: electrical and electronical products, mechanical and car body products as well as cooling systems. The article Based on the Interview with Mr. Adriano Fontana Magneti Marelli President. ‘IMPROVING THE ENVIRONMENT IS NOT A GOAL FOR THE FUTURE, BUT SOMETHING WE CAN DO RIGHT AWAY’… FIAT AUTO POLAND S.A. The Tychy Factory, the largest automobile factory in Poland, the biggest Fiat factory in Europe and the second in the world after the Brazilian one. I hope that each of you will find an interesting subject in the publications which are brought to you in this issue, and we believe that trough this journal we can pave the way for mutual success.
Prelude Księga1.indb 3
Editor:
Manufacturing-Journal | 1 | 2010-04-28 14:52:16
CONTENTS
Contents: Editor Patryk T. Zborowski
1 2 4 10
Profile Writers Aleksandra Strojek Anna Chudzik Bartosz Sowiński Berenika Wilczyńska Karolina Burkiewicz Kateryna Ferdyn Łukasz Światowiec
Prelude Contents News Country profile
Art Director Wojciech Kosmowski Project Managers Agnieszka Bechta-Ziobro Marta Kaciupska Katarzyna Marciniec Katarzyna Olszowska Administration Wioletta Adamczyk
12 The Polish GEM of GM 16 Buses from Poland for the world’s roads 22 Light trailers for everyone 26 A recognized professionalism 29 International leader of high-tech systems for automotive industry 34 Working with the giants 37 The most ecological brand in Europe 42 How to invest in style 45 Bright lights, bright future 48 Offering integrated logistics solutions 51 Top quality solutions for transportation
Z-MEDIA Długa Street 48/38 31-146 Cracow Poland e-mail: info@manufacturing-journal.net advertising: pz@manufacturing-journal.net phone number 1: 0048 12 4337115 phone number 2: 0048 12 4337065 phone number 3: 0048 12 4337066 fax number: 0048 12 4337116 web: www.manufacturing-journal.net
© Manufacturing Journal 2010 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.
| 2 | Manufacturing-Journal Księga1.indb 4
Contents 2010-04-28 14:52:17
NT EN TS CO
Experienced in Italy, effective in Poland Passion of creation Steering towards modernity Running like clockwork World-class plastic components A roof over your head
Index:
54 57 60 63 66 70
Articles:
Automatyka Sp. z o.o. Biazet S.A. BITRON POLAND Sp. z o.o. CMT Chojnice Sp. z o.o. F.P.U.H. BLACH-STAL Paweł Skawski Fabryka Osłonek Białkowych FABIOS S.A. Fabryka Osprzętu Samochodowego „Polmo” Łódź S.A. Fermy Drobiu Woźniak Sp. z o.o. FESCO Transportation Group FIAT AUTO POLAND S.A. GENERAL MOTORS MANUFACTURING POLAND Sp. z o.o. Groupe Plastivaloire Eastern Europe JSC Sarmat MAGNETI MARELLI PAS Polska Sp. z o.o. Scania Production Słupsk S.A SEGU POLSKA Sp. z o. o. SIMOLDES PLASTICOS Polska Sp. z o.o. SORELPOL Sp. z o.o. Truck-Lite Europe Sp. z o.o.
Advertising:
The goose that lays golden eggs 74 The spirit of freedom 79 One of a few in Europe – one of a kind 82
Altuglas International S.A. Astromal Sp. z o.o. AURES Sp z o.o. BIG DUTCHMAN POLSKA Sp. z o.o. CESMEX DAGAT-eco sp. j. Diversey Inc. ELGUM AUTOMOTIVE Sp. z o.o. F.H.U. NEW-TON GEDIA POLAND ASSEMBLY Sp.z o.o. GESTAMP Polska Sp. z o.o. ITIB Poland Sp. z o.o Marcato Sp. z o.o. MOBA B.V. ORSA-MOTO Sp. z .o.o. PRO-CARS S.j. PROTECH Kania Maciej Steelpress Sp. z o.o. SUNKISS Polska Sp. z o.o. Tekspol Sp. z o.o. TENNECO AUTOMOTIVE POLSKA Sp. z o. o. WITAL Ludwik Witczak Z.P.U. Profes s.c.
Contents Księga1.indb 5
63 60 54 51 70 82 34 74 48 37 12 66 79 29 57 16 26 42 22 45
9 18 30 76 67 20 81 33 27 14 37 54 76 77 38 38 39 23 67 31 14 23 67
Manufacturing-Journal | 3 | 2010-04-28 14:52:18
NE W S
Good start to the new fiscal year Bosch expects substantial recovery following the crisis year 2009
al measures that were needed. More info: www.bosch.com
Production and Sales of ‘Camry Hybrid’ Begin in China
Volvo Trucks launches new construction truck
The Bosch Group has made a good start to the current fiscal year, and intends to make up for much of the loss of sales in 2009 this year. At the Annual Press Conference in Stuttgart, Franz Fehrenbach, the chairman of the Bosch board of management, said: “We want to return to a positive result in 2010.” There were clear signs of recovery in all regions, he said, with an especially powerful boost coming from the markets in China and India. In the first quarter of this year, Bosch Group sales were up roughly 25 percent year on year. But the first quarter of 2009 was also the lowest point of that crisis year, so current sales are still significantly below their 2007 level. All in all, sales in the current fiscal year are expected to grow by more than 10 percent, to 42 billion euros. Due to increased demand for vehicles, especially outside Europe, automotive technology will make the greatest contribution to this growth. However, Fehrenbach warned that recovery should not be “taken for granted.” As a result of the crisis, he pointed out, Bosch had lost ground when it came to productivity. This was why it was decisive to lay the foundations for the future now, and not to let up with the structur-
| 4 | Manufacturing-Journal Księga1.indb 6
Volvo Trucks has today launched its new Volvo FMX construction truck at the Bauma international machinery fair in Munich. With this new truck, Volvo Trucks aims to secure a strong increase in its market share of the construction segment. Volvo FMX is based on the FM truck, which itself is a successful and well-tested construction truck. Sales of the new truck in the European market will commence in September. An international launch will follow during the remainder of the year. “Today, Volvo Trucks is the leader in the long-distance transport segment and we are now aiming to take a leading position in the construction segment,” says Staffan Jufors, President of Volvo Trucks. The Volvo Group is unique in the vehicle industry as a leading producer of trucks and construction equipment. No other producer has this type of experience. “Volvo Trucks and Volvo Construction Equipment have extensive experience of the construction industry. In combination, we can offer our customers the most comprehensive product offering in the industry. We intend to capitalize on this to grow Volvo Trucks’ presence in the construction segment. We foresee great potential in this area,” says Staffan Jufors.
More info: www.volvogroup.com
Toyota Motor Corporation (TMC) announces that today GAC Toyota Motor Co., Ltd. (GTMC), TMC’s joint vehicleproduction and sales company with Guangzhou Automobile Group Co., Ltd. (Guangzhou Automobile) in China, held a ceremony and press conference in Guangzhou, Guangdong, to mark the beginning of production and sales of the “Camry Hybrid” sedan. Sales start at 107 of GTMC’s dealers but are planned to eventually expand to its entire dealer network. Approximately 350 people attended the ceremony, including local and central government officials, various suppliers, dealers and members of the media. More than half a million units of the non-hybrid “Camry” have been sold in China between its launch there in June 2006 and the end of February 2010. Plans call for the Camry Hybrid to be priced between 319,800 yuan and 364,800 yuan. TMC has been actively carrying out business activities aimed at popularizing hybrid vehicles in China. At the end of 2005, the “Prius” became the first hybrid vehicle to be launched in China. The Prius was followed in 2007 by the hybrid version of the Lexus-brand flagship, the “LS600h” luxury sedan, and the Lexus “RX400h*” SUV. The Camry Hybrid follows the Lexus “GS450h” sports sedan, launched in 2009, to become the fifth Toyota- or Lexus-brand hybrid vehicle launched in China. More info: www.toyota.co.jp
News 2010-04-28 14:52:19
NEWS
LG strengthens bonds with suppliers at third global supplier’s day Ford showcases new products and technologies at largest-ever Beijing Auto Show Exhibit Soon after the 500,000th Ford Focus production milestone in China, the global preview tour of the next-generation Ford Focus provides an exciting look at the future five-door hatchback model. Debut of the Ford Edge mid-size sport utility vehicle with next-generation MyFord and SYNC technologies. Ford Mondeo to get 2.0-litre Ford EcoBoost engine and PowerShift transmission in 2010. Ford Start Concept, an exploration into a small, sporty car for first-time buyers and urban drivers in future growth markets, features a new 1.0-litre EcoBoost engine, which Ford is confirming for production. Ford EcoBoost engine technology, which combines direct fuel injection and turbocharging, is one of the technologies behind Ford’s commitment to improve fuel efficiency by up to 20 percent across the regional product lineup by 2012. Ford’s stand in Beijing is its largest ever in China, with 17 interactive stations complementing the new vehicles and technologies.
LG Electronics (LG), a global leader and technology innovator in consumer electronics, today met with over 350 supplier companies from inside and outside Korea at the third Global Supplier’s Day held in Seoul. This annual event allows LG to forge closer relationships with its global partners and helps shore up the competitiveness of all companies involved through the innovation derived from global cooperation. With the event focusing mainly on open innovation – LG executives met with more than 1,000 representatives from suppliers around the world. Among the speakers at the event was Derek Lidow, CEO of iSuppli, who delivered a compelling address called “Where the Wild Things Are: Innovation in the Electronics Jungle” which stressed the ongoing importance of innovation at electronics companies. Hosted by Thomas Linton, Executive Vice president and Chief Procurement Officer (CPO), the Global Supplier’s Day was attended by LG Electronics CEO Yong Nam, the heads of LG Electronics’ five business units, as well the CEO or Senior Executives of major suppliers such as Microsoft, Qualcomm, Hynix, Sanyo and Toshiba Semiconductor.“We had great achievement last year because of our
supplier’s contribution. However, we are now facing big challenges this year.” said LG CEO Yong Nam. “We’d like to innovate together and also we’d like to work together to have a sustainable relationship going forward.”Linton took the opportunity to show the attendees a new official website aimed at fostering collaborative innovation between LG and its suppliers. In addition, he introduced everyone to LG’s new Global Procurement Policy, published in January of this year, and the company’s Green Initiatives, which aim to promote sustainable growth and save energy throughout a product’s entire life cycle. Showing their more charitable side, LG and its partner companies took part in an auction of memorabilia from the event, with all proceeds going to Good Neighbors International, a Koreabased humanitarian NGO. And LG’s most esteemed suppliers received one of 14 awards, including Hynix Semiconductor, which received the top global supplier award for its invaluable contribution. More info: www.lg.com
More info: www.ford.com
News Księga1.indb 7
Manufacturing-Journal | 5 | 2010-04-28 14:52:20
NE W S
BMW Group aims for major increase in sales in China
• • •
Deliveries of around 120,000 vehicles targeted in 2010 BMW Active E will launch as test vehicle in China in 2011 Reithofer: Megacity Vehicle will be on the market in 2013
The BMW Group is aiming for a larger increase in sales volumes in China this year than originally planned.“China is, and will
remain, one of the most attractive automobile markets in the world. We expect to see significant sales growth to around 120,000 vehicles in China in 2010,” said Chairman of the Board of Management of BMW AG, Norbert Reithofer, at the Auto 2010 motor show in Beijing on Friday. The company had previously been targeting a sales volume of more than 100,000 automobiles. China is currently the BMW Group’s fourth largest market worldwide. Last year the company sold more than 90,000 vehicles in mainland China. In the first quarter of 2010, deliveries increased by 106% to reach a total of 34,179 vehicles. The BMW Group is also on course for growth worldwide in 2010: “We intend to remain the world’s leading premium manufacturer in 2010 and achieve healthy sales growth in the single-digit percentage range to reach more than 1.3 million vehicles,” affirmed Reithofer. More info: www.bmwgroup.com
Audi sells most all-wheel-drive vehicles worldwide No other premium car manufacturer sells as many vehicles with all-wheel
drive throughout the world as does Audi. Last year the Ingolstadt-based carmaker built 316,824 cars with quattro drive. This means that around a third of all the Audi cars leaving the factory in 2009 were equipped with this successful technology. Top seller among the all-wheel-drive models last year was the Audi Q5, with 109,117 produced. In Germany, too, Audi’s quattro drive has outperformed its competitors. The brand delivered 72,049 all-wheel-drive vehicles to customers in 2009 and thus took first place in the premium segment. In the year in which quattro celebrated its thirtieth anniversary, two Audi models won the “All-Wheel-Drive Car of the Year” poll. Readers of “AUTO BILD ALLRAD” voted the Audi A4 quattro and the Audi A8 top of their categories. MichaelJulius Renz, Head of Sales Germany at AUDI AG, was presented with the award
Modern Luxury on Grand Scale Will Be Displayed When Infiniti QX56 Debuts at 2010 Beijing International Automobile Exhibition Infiniti will debut the 2011 QX56 luxury full-size SUV at the Beijing International Automobile Exhibition, April 23 to May 2. The luxury automaker also will feature the 2010 FX sport utility vehicle, EX25 coupe crossover, G37 convertible and G25 premium sport sedan. Essence, the concept car inspired by a single brush stroke, will be displayed as well and is expected to wow show-goers with its stunning design and 600 PS. Infiniti QX56 is a full-size luxury SUV offering
| 6 | Manufacturing-Journal Księga1.indb 8
News 2010-04-28 14:52:21
NEWS
on Thursday evening at an event held during the AMI show in Leipzig. It was the fifth year in succession that the prize had gone to the Ingolstadt-based company. “Back then it was a truly pioneering act to venture along a new engineering path and launch the original quattro,” says Renz. “But the true secret of the success achieved by quattro is that we have regularly reinvented it. For example, we recently introduced the crown-gear center differential on the RS 5. The quattro drive may be thirty years old – but it’s still very much a future oriented technology.” The spotlights went on to showcase the first Audi quattro on March 3, 1980 at the Geneva Motor Show. A series of motorsport victories began, and the success of this all-wheeldrive system on both road and track was assured. Today, it is still one of the manufacturer’s core competences and a major element in the Audi model initiative.
Mitsubishi. The PCMA Rus plant will be an extremely compact factory, with optimised workspace divided between just two buildings: one for the paint shop, and one for the body in white and assembly workshops. In order to reduce its environmental footprint, the plant will adopt the best practices from its parent companies for energy saving, reduction of CO2 emission and waste reduction (use of water based paints only, sustainable packaging for shipment). The plant will employ about 3,000 people, from which approximately 2,600 will be trained at the local training centre built in cooperation with the Government of the Kaluga Region.
PSA Peugeot Citroën and Mitsubishi Motors Corporation begin production at their jointly owned plant in Kaluga (Russia)
Philippe Varin, Chairman of the Managing Board of PSA Peugeot Citroën, and Takashi Nishioka, Chairman of Mitsubishi Motors Corporation, have officially started vehicle production at PCMA Rus, their joint plant in Russia. The plant, which is owned 70% by PSA Peugeot Citroën and 30% by Mitsubishi Motors Corporation, is located at Kaluga, 180 km South-West of Moscow. The ceremony took place in the presence of Mr. Georgi Poltavchenko, Presidential Plenipotentiary Envoy to the Central Federal District, and Mr. Anatoly Artamonov, Governor of the Region of Kaluga. This plant, which represents a joint initial investment of €470 million, will enable PSA Peugeot Citroën and Mitsubishi Motors Corporation to become major players in the Russian automotive market, whose growth potential is significant. From April 2010 the Kaluga plant will produce the Peugeot 308, followed by the Citroën C4 and the Citroën C-Crosser, Peugeot 4007 and Mitsubishi Outlander SUV models. These models target the mid-range segments of the Russian market. The plant will be fully operational in 2012. From that date, the annual production capacity of the plant will be 125,000 units, split 85,000 mid-range sedan vehicles for Peugeot and Citroën and 40,000 midrange SUVs for Peugeot, Citroën and
an outstanding combination of refinement, roominess, advanced technology and power. Its sophisticated exterior design and comfortable interior space, with versatile cargo area, will attract an active affluent family, who seeks the full complement of luxury and comfort in life. The car is available with a 441PS 5.6-liter V8 engine and Infiniti All-Mode 4WD system. Among its many features are Intelligent Cruise Control, the Infiniti Mobile Entertainment System and RearView Monitor. With the debut QX56, which launches here in late 2010, the complete lineup of Infiniti products will be available in China. Also a feature at the Infiniti Pavilion is the 2010 FX series. The performance crossover FX35 and FX50 come with a 431PS 5.0 liter V8 en-
gine or a 332PS 3.5-liter V6 engine and a seven-speed automatic transmission, Advanced Climate Control System, Intelligent Brake Assist with Forward Collision Warning and Intelligent All-Wheel Drive, among other features. All 2010 FX series models now are equipped with Chinese Menu, Real-Time Traffic and Dynamic Route Guidance and Scratch Shield Paint technology. FX50 is priced at 1,202,000 RMB, and FX35 is priced at 783,000 / 816,000 RMB. The Infiniti Story In just three years, Infiniti has made significant advances into the Chinese market by expanding the product lineup and developing its sales and service network. As part of the Infiniti Retail Environment Design Initiative, Infiniti has es-
tablished 19 dealerships in major cities in most regions across the country and hopes to grow that to more than 30 by the end of 2011. Infiniti has continued its sales momentum in 2010 with growth of 184 percent in the first quarter over the prior year. Driven by the strong Infiniti product lineup, the company has targeted sales of 10,000 units for the year.
More info: www.audi.com
News Księga1.indb 9
More info: www.psa-peugeot-citroen.com
More info: www.nissan-global.com
Manufacturing-Journal | 7 | 2010-04-28 14:52:22
NE W S
TRADE SHOWS 12.05 - 16.05 2010
CAR + SOUND 2010
All-new Verna is Hyundai’s 3rd China-exclusive model - Hyundai holds world premier in China Beijing, China) Hyundai Motor Co. staged the world-premiere of its all-new Verna at the 2010 Beijing Automotive Exhibition today. With its eye-catching sloping roofline, the new subcompact, Hyundai’s third China-exclusive model, projects a coupe-like dynamic image that is at once sporty, stately and futuristic. Developed over a five-year period expressively for the Chinese market, product planners conducted exhaustive market research of Chinese consumer tastes and trends to ensure every detail meets local requirements. Built on an all-new platform at the company’s highly automated plant in Beijing, Verna is targeted at China’s strategically important C1 segment and fully reflects Hyundai’s philosophy of quality. “Today is a really special day for us, not only because we’re launching a new car, but because it’s one of the very few times we’ve done a world-premiere outside of Korea: And we chose to do it right here in China because it’s our way of recognizing how important our Chinese customers are to us,” Euisun Chung, Vice Chairman of Hyundai Motor said today at the Beijing auto show. “In 2009 we posted a 94 percent Y-o-Y growth in China and have sold over 2 million cars since arriving in 2002. We are not losing any momentum, continuing to expand our lineup in China with our most stylish and advanced models like the all-new Verna and our compact SUV “ix35.” To minimize fuel consumption without sacrificing performance, Verna is powered by the new generation Gamma gasoline engine, featuring multiport fuel injection. Verna delivers best-in-class fuel economy, in keeping with Hyundais pledge to be the industrys eco-leader. And it fully satisfies China’s Step 3 fuel economy regulations ? two years ahead of schedule.
Leading Show for Mobile Electronic in Europe Venue: Messegelände Friedrichshafen Neue Messe 1 88046 Friedrichshafen Germany www.schall-messen.de/_s/carsound 18.05 - 21.05 2010
MOTOREXPOSHOW 2010 Exhibition of motor-cars and lorries Venue: Siberia International Exhibition Business Centre 19, Aviatorov Street Krasnoyarsk city Russia www.krasfair.ru/eng/main/index.shtml 05.06 - 10.06 2010
AUTOSALON BRNO 2010 International Motor Show Venue: Brno Exhibition Centre Vystaviste 1 64700 Brno Czech Republic www.bvv.cz/autosalon-gb
More info: www.worldwide.hyundai.com
25.08 - 29.08 2010
MIMS 2010 Moscow International Motor Show Venue: Crocus-Expo IEC Krasnogorsk 65-66 km Moscow Ring Road Russia www.motorshows-ite.com
| 8 | Manufacturing-Journal Księga1.indb 10
News 2010-04-28 14:52:22
NEWS Altuglas International, worldwide leader in PMMA resins is developping Innovative Solutions for its customers; • • • •
High gloss opaque grades for automotive trims High temperature and scratch resistance grade (Altuglas® HT 121) for rear lights and electrical appliances High performance resins for coextrusion on ABS and PVC Frosted and Matt grades for visual effects for both automotive and electrical appliances.
These new products bring cost effective and environmental friendly solutions (no coating required and one step processes)
TRADE SHOWS
Together with our customers, our sales and development teams build up real partnerships which create value for both parties.
27.08 - 05.09 2010
CARAVAN SALON DÜSSELDORF International Motor Homes and Caravans Exhibition
CEM KIEV 2010 International Forum of World (global) and Domestic Leaders in the Field of Home Appliances and Electronics
Venue: Düsseldorf Exhibition Centre Stockumer Kirchstr. 61 D-40474 Düsseldorf Germany www.caravan-salon.de
Venue: Kiev International Exhibition Center 15, Brovarsky Ave Kyiv Ukraine www.cem.com.ua
03.09 - 05.09 2010
19.11 - 21.11 2010
AUTO MOTOR SHOW LJUBLJANA
INTELLIGENT HOME 2010
The biggest Car, Motorbike, Car Audio and Tuning event in Slovenia
Vision of Digital Home. Domestic Electronics, Technical Equipment and most advanced IT Technologies for Daily Life Venue: Lithuanian Exhibition Centre (Litexpo) Laisves Ave.5 LT- 2600 Vilnius, Lithuania www.litexpo.lt/en
Venue: Ljubljana Exhibition and Convention Centre Dunajska c. 10 1000 Ljubljana www.automotorshow.si/english
News Księga1.indb 11
Nov. 2010
Manufacturing-Journal | 9 | 2010-04-28 14:52:24
C PR OU O NT FI RY LE
Germany
Full name: Federal Republic of Germany Population: 82.2 million (UN, 2009) Capital: Berlin Area: 357,027 sq km (137,849 sq miles) Major language: German Major religion: Christianity Life expectancy: 77 years (men), 82 years (women) (UN) Monetary unit: 1 euro = 100 cents Main exports: Motor vehicles, electrical machinery, metals GNI per capita: US $42,440 (World Bank, 2008) Internet domain: .de International dialling code: +49 Located in the heart of Western Europe, Germany is the continent’s most industrialized and populous country. Famed for its technological achievements, it has also produced some of Europe’s most celebrated composers, philosophers and poets. Achieving national unity later than other European nations, Germany quickly caught up economically and militarily, before defeats in World War I and II left the country shattered, facing the difficult legacy of Nazism, and divided between Europe’s Cold War blocs. Germany rebounded to become the continent’s economic giant, and a prime mover of European cooperation. With the end of the Cold War, the two parts of the country were once again united, but at an economic price that is still being felt.
Overview
People in the previously affluent west have had to pay a higher price than many originally expected while those in
what was once the German Democratic Republic, the former Soviet-dominated east, saw jobs vanish and the cost of living spiral. The population is declining there too as young people vote with their feet. The pain of Germany’s Nazi-era history remains a sensitive element in the country’s collective modern-day psyche. Out of the devastation of World War II grew European awareness of the need to guard against any such catastrophe recurring on the continent. In the 1950s Germany was one of the six founding nations in the original European Economic Community from which the European Union was eventually to develop and in which Germany is a key player. Franco-German cooperation was central to European economic integration in the 1980s and 90s. Germany’s international profile has been growing in other areas too. The country sent peacekeepers to the Balkans and its forces have been involved in operations
in Afghanistan. The former chancellor, Gerhard Schroeder, was a vociferous critic of the launch of US-led operations in Iraq. The country has famous beer brewing traditions. Beer purity laws dating back to 1516 limit the fermentation ingredients to malted grain, hops, yeast and water. As the birthplace of Johann Sebastian Bach, Ludwig van Beethoven and Johannes Brahms, among others, Germany’s gift to European classical music is colossal while Goethe, Nietzsche, Kant and Brecht are giants in the world of letters and philosophy.
Leaders President: Horst Koehler The president has a mainly ceremonial role. Horst Koehler, a former head of the International Monetary Fund (IMF), was elected in May 2004, and re-elected for another five-year term in May 2009.
The Reichstag in Berlin is the site of the German parliament.
| 10 | Manufacturing-Journal Księga1.indb 12
Country Profile 2010-04-28 14:52:25
COUNTRY PROFILE
Drezno
Chancellor: Angela Merkel Angela Merkel, Germany’s first female chancellor, swept back to power in general elections in September 2009. Mrs Merkel, leader of the conservative Christian Democrats (CDU), first took office in 2005 when general elections produced a very close result. She became chancellor in a „grand coalition” involving the CDU, its Christian Social (CSU) allies and the Social Democratic Party (SPD). In 2009, her party secured another four-year mandate with enough votes to dump the previous awkward coalition with the Social Democrats in favour of an alliance with the pro-business
Free Democrats (FDP). After more than three weeks of hard bargaining, the CDU and FDP sealed a coalition deal when they finally reached agreement on a tax cuts package. The coalition faces some tough challenges. Germany’s export-dependent economy was hit hard by the global financial crisis of 2008-9, which triggered the worst recession since the foundation of the post-war Federal Republic in 1949. The recession has left Germany’s public finances in tatters, making it hard to honour pre-election promises to slash taxes, and the exact figure to be cut proved to be the thorniest issue in the coalition talks. On issues such as healthcare, nuclear power and fore-
Düsseldorf
Country Profile Księga1.indb 13
ign policy, the CDU and FDP - who have a long history of being in coalition - found it much easier to reach agreement. During her first term in office, Mrs Merkel steered a centrist course at home and earned a reputation as a talented mediator at the international level. She was born in Hamburg in 1954 but grew up in East Germany where her father was a Protestant clergyman. She holds a doctorate in physics. She became leader of the CDU in 2000 after Helmut Kohl was brought down by a party funding scandal. In 2009 Mrs Merkel topped Forbes magazine’s list of the world’s 100 most powerful women for the fourth year in a row. The magazine said that she had won respect for her cool leadership, and cited her achievement in getting G8 leaders to agree to goals for cutting greenhouse gas emissions and in persuading European Union leaders to move forward from the failure to secure a constitution. The global financial crisis of 2008-9 posed an even tougher challenge. Germany experienced its worst slump in output for more than 60 years, but Mrs Merkel’s calm handling of the crisis won her respect both at home and abroad. She divorced her first husband Ulrich Merkel in 1982 and has been married to publicity-shy chemistry professor Joachim Sauer since 1998. She has no children. She is a fan of classical music, regularly attending the annual Bayreuth opera festival, and enjoys hiking in the Alps in her free time.
Manufacturing-Journal | 11 | 2010-04-28 14:52:27
S TI CL E AR
The Polish GEM of GM
G
eneral Motors, one of the world’s largest automakers, has been a synonym for excellence in the automotive industry since it was founded in 1916. Every year the concern sells millions of cars and trucks globally under such brands as Buick, Cadillac, Chevrolet, GMC, GM Daewoo, Holden, HUMMER, Opel, Pontiac, Saturn, Vauxhall and Wuling. With global headquarters in Detroit, General Motors has its manufacturing operations in 34 countries, including a Polish factory in Gliwice (General Motors Manufacturing Poland). Specializing in the Opel cars production, it is one of the most modern plants of General Motors in the world.
Beginnings of
General Motors in Poland The history of General Motors Poland dates back to 31 May 1991, when the company was General Manager GMMP registered and Mr. Antonio Francavilla started importing the Opel cars to the country. Owing to the political transformation, which entailed the beginning of free market economy, and the lack of competition at that time the Polish market seemed potentially attractive to foreign investors. From the initial stages of its activity General Motors Poland developed rapidly – as soon as in 1992 it already had 25 and retail outlets and 14 authorised service station. Currently, the sales network of Opel in Poland consists of 68 main dealer stations and 29 satellite points. When it comes to the service, the number of service centers grew to 72 main and 27 satellite ones. The business activity of General Motors Poland revolves around import, after-sale service as well as production of the Opel brand.
Production activity
The production activity at General Motors Poland started in 1994 with assembling Opel Astra in Warsaw, followed by the Vectra model four years later. The Warsaw assembly plant ceased to exist by June 2000 after the plant in Gliwice became the main GM production centre in Poland. General Motors invested about EUR 700 million in General Motors Manufacturing Poland (formerly known as Opel Polska). Having been built in only 22 months, the cutting-edge as-
| 12 | Manufacturing-Journal Księga1.indb 14
sembly plant in Gliwice was opened in 1998 and immediately started production of Astra Classic, which was the first model manufactured at the site. In 2000 the Gliwice factory, as the only GM plant in the world, launched the assembly of the Opel Agila. Nowadays GMMP produces three Opel models: Zafira (the 7-passenger compact MPV vehicle), Astra III NB and, from November 2009, Astra IV.
The investment which has paid off
The plant in Gliwice is the largest foreign investment in the Katowice Special Eco-
FACT BOX
FULL NAME: GENERAL MOTORS MANUFACTURING POLAND Sp. z o.o. GENERAL MANAGER: Antonio Francavilla OPERATIONS: Automotive ESTABLISHED: 1998 EMPLOYEES: 2500
www.gm.com www.opel.com.pl
Automotive IndustryGeneral Motors 2010-04-28 14:52:32
nomic Zone. Employing approximately 3000 people, the plant gave a boost to the region and had a positive impact on the industry. Within the last years, the exports amounted to 82% of the production, which constituted around 1,4% of the domestic exports in 2008. It can be easily noticed that General Motors has made a significant contribution to the development of the Polish economy. Apart from the export revenues, the concern has been actively promoting Poland, recommending it as an investorfriendly country. Moreover, intensive cooperation with Polish suppliers has contributed to the significant growth in their number. They supply products and services not only to GMMP in Gliwice, but also to other GM units around the world, which makes it possible to create additional workplaces. In 2004 the daily Gazeta Prawna awarded GM the prize for the best foreign investment in Poland within 15 years from 1989 to 2004.
The ISO policy
The success of the investment in the Gliwice plant lies in a variety of factors. The most important ones are modern methods of management and production, highly qualified staff, top quality of products and concern for the environment. The quality of products has been certified by comprehensive reports, which included the opinions of customers from top European markets. Moreover, in 1999 the plant received the certificate in accordance with the ISO PN-ISO 9002 norm, which was granted by two independent certifying institutions – KBA (Kraftfahrt Bundesamt) from Dresden and PCBC (Polskie Centrum Badań i
Certyfikacji – Polish Centre for Testing & Certification) from Warsaw. Controls carried out later in time confirmed the factory’s compliance with all the requirements of the norm. Since the overriding aim of GMMP is to produce cars of prime quality with a view to the protection of the environment, the management of the plant decided to implement the Integrated Quality Management System (ISO 9001:2000) and Environmental Management System (ISO 14001), for which the certificates were granted in 2002. Based on the guidelines included in the norms, the factory compiled “The Integrated Management System Policy”, which contains its commitments referring to the quality of goods and protection of the natural environment. According to the policy, the company strives to be the world-class factory, devoted to improving products and services, taking care of the employees’ safety as well as their professional development and making use of innovative technologies. When it comes to reducing the negative impact on the environment, the plant uses eco-friendly solutions, e.g. in a paint shop, which was designed and built in accordance with stringent EU standards. Car bodies are covered with an innovative lead-free, anticorrosive paint, while all priming paints and surface coats are made in the water dilution technology, which entails no harmful emissions of fumes from organic solvents. Owing to state-of-the-art varnishing robots, as well as the presence of a sewage-treatment plant on site, the plant reduces the amount of waste material to the minimum.
Automotive IndustryGeneral Motors Księga1.indb 15
Manufacturing-Journal | 13 | 2010-04-28 14:52:38
Tenneco Automotive Polska in Rybnik, which is a part of the American corporation TENNECO, was established in July 1997. The company specializes in production of exhaust systems. As early as December 1997, thanks to creating a dynamic team of workers, the company was able to manufacture the first part of Walker mufflers. The location of the production plant in Rybnik was not accidental. The most principal strengths of the city, which have contributed to development of the company, include its convenient geographic location, proximity to major transportation connections and significant recourses of qualified labour force.
Growth. The thirteen years of the company’s operation include permanent growth and improvement of production in order to achieve international standards of the automotive market. The company, which in the beginning manufactured about 150 types of mufflers, today manufactures more than 3000 types of exhaust systems. Tenneco Rybnik is equipped with the modern technology and machines. Rybnik Engineering Center develops and tests exhaust systems for Tenneco demanding customers. Tenneco produces and supplies for such leading customers as: GM, AUDI, BMW, FIAT, FORD, JAGUAR, MERCEDES, OPEL, VOLKSWAGEN, VOLVO, PSA, TOYOTA. Opel INSIGNIA and ASTRA are also equipped with exhaust systems from Rybnik plant.
Innovations. In a recent period our company started production of exhaust systems equipped with catalytic converters and Diesel Particulate Filters (DPF) – meeting European cleanliness standards for exhaust systems. Tenneco plant in Rybnik produces also mufflers for BMW motorcycles.
TENNECO AUTOMOTIVE POLSKA Sp. z o. o. ul. Przemysłowa 2C, 44-203 Rybnik
www.tenneco.com
Quality. Tenneco customers’ high quality requirements are governed by Quality System according to the automotive standard ISO/ TS 9001: 2002 and Environmental System ISO 14000.
tel.: + 48 32 4292 100 fax.: + 48 32 4294 280 rybnik@tenneco.pl
GEDIA POLAND ASSEMBLY SP.Z O.O. UL. Przemysłowa 7 67-100 Nowa Sól phone: +48 68 4563 402 fax: +48 68 4563 444 e-mail: a.niesyto@gpl2.gedia.com www.gedia.com
GEDIA POLAND ASSEMBLY produces body - car’s components for the latest car model OPEL Astra (GM Opel Gliwice, GM Opel Ellesmere Port -UK) Complete front left and right longitudinal Elements of the rear left and right longitudinal
| 14 | Manufacturing-Journal Księga1.indb 16
Automotive IndustryGeneral Motors 2010-04-28 14:52:43
Non-business activity achievements
The activity of General Motors in Poland also consists in its commitment to social and charity undertakings. To give an example, GM was involved in building „Houses of Hope” – the project realized in cooperation with an international organization Habitat for Humanity. Another initiative was directed towards young people – 18,000 have paid educational visits in the plant so far. Among other programs there was one called Plato, aimed at small and middle companies from the Silesia region. GM also organized a jubilee concert for the inhabitants of Gliwice and the nearby area. Success achieved by General Motors Poland as well as General Motors Manufacturing Poland was attested by various institutions, which rewarded the companies with prestigious titles and distinctions. Among them there are: the title “Investor of 1999 for GM Poland and Opel Polska”, granted by Polski Klub Biznesu, the awards of the General Motors’ President (1999, 2000, 2001, 2003 and 2004), the distinction „For the Renovator of the Polish Industry” („Dla Tego, który Zmienia Polski Przemysł”) by The Association of Enterprise Support (Towarzystwo Wspierania Przedsiębiorczości) (2000), “The Economic Prize of the President of Poland” (“Nagroda Gospodarcza Prezydenta RP”) in the category “Best Foreign Investments in Poland in 2000” (2001) or the title “Benefactor of the Year 2001” (“Dobroczyńca Roku 2001”) by Academy for the Development of Philanthropy in Poland (Akademia Rozwoju Filantropii w Polsce) (2002). Having been granted the “Employer of the Year” titles for several times, GMMP was also widely
recognized as a reliable employer in the Katowice Special Economic Zone and in the whole of Poland. When it comes to products which leave the assembly line at GMMP, Opel Astra IV deserves particular attention. It won the awards „Golden Wheel” (“Złota Kierownica”) in a poll organized by the Auto Świat magazine (2009), as well as ”The Best Cars in 2009” („Najlepsze Samochody roku 2009”) (2010) and the “Auto Leader 2009” (2010) by the Auto Motor i Sport magazine. Written by Anna Chudzik
Automotive IndustryGeneral Motors Księga1.indb 17
Manufacturing-Journal | 15 | 2010-04-28 14:52:58
S TI CL E AR
Buses from Poland for the world’s roads
S
cania Production Słupsk S.A. is a Poland-based manufacturing plant of the world-known Swedish concern Scania – a leading manufacturer of heavy trucks, buses and coaches as well as industrial and marine engines, which operates in about 100 countries and employs more than 34,000 people. The company’s production facilities are found in Sweden, France, Netherlands, Brazil, Argentina and Poland, where the Słupsk plant specializes in the production of buses for public transport and bus chassis.
Scania in the world
Scania is one of the biggest and the oldest producers of vehicles in the world with the rich tradiPlant Manager tion dating back Mr. Gert Flodkvist to 1891, when the plant producing railway carriages called Vabis was found in the Swedish city Södertälje. The other root of today’s company is Maskinfabriksaktiebolaget Scania, the plant set up in Malmö to
FACT BOX
FULL NAME: Scania Production Słupsk S.A. PLANT MANAGER: Gert Flodkvist VICE PLANT MANAGER: Sylwester Wojewódzki OPERATIONS: Automotive ESTABLISHED: 1992 EMPLOYEES: 750
www.scaniaproductionslupsk.pl
| 16 | Manufacturing-Journal Księga1.indb 18
originally produce bicycles, which built its first passenger car as well as its first truck in 1902. Eventually Scania and Vabis merged in 1911 so as to meet the market demands in Europe and started the production of buses. In the 1950s Scania-Vabis commenced creating sales and service network in Europe, while in the next decade it established manufacturing facilities in several other sites in Sweden and abroad. The company decided to internationalize its operations and create plants in Argentina, Brazil, France, Netherlands and also in Poland. In addition to sales and service, Scania also offers financial services on most markets.
stringent. When the customs duty was eventually abolished, there was no more reason for assembling trucks in Poland, so the company ceased this activity in 2002. What is more, in a Dutch city, Zwolle, Scania had built an enormous production plant, capable of assembling more than 150 trucks a day. Anyway, the Słupsk plant is a unique facility, since it fulfills all the functions ranging from production, logistics, purchase, flow of materials, assembly lines operations to delivery. Although trucks remain the main Scania product, buses manufactured in Słupsk enjoy growing popularity among customers.
Choice of Słupsk
Słupsk, a city in the northern part of Poland, was chosen as a location of the Scania plant in 1992, when the concern looked for a partner to assemble trucks, as it was a necessary condition for entering the Polish market. At that time the plant of Kapena – the company which specialized in the repair of buses – was faced with a challenge to find a strategic partner. The most crucial elements for the Swedish in the choice of location were the proximity to the Baltic ports, the size of the facility as well as abilities of the staff. Moreover, Kapena had already achieved a stable position in the Polish market. As a result, after concluding a joint-venture contract, the company started reorganizing its business profile. The first Scania trucks in Poland were manufactured in June 1993, while the first buses left the assembly line in 1994. Since April 1995 the plant in Słupsk has been producing bus chassis. In 2000 the production of trucks was curbed due to the customs regulations which were becoming less and less
Automotive IndustryScania Production Słupsk 2010-04-28 14:53:01
Popularity of the Scania buses
The bus business in Słupsk has been flourishing since the very beginning. In 1994, which was the first year of production, only 5 buses were assembled. The next year the number tripled, while in 1998 it amounted to 47. In 2009 as many as 903 buses left the assembly line, among them the 3000th one to be manufactured in the plant. The ever-growing popularity of the buses has been reflected in the sales figures – in 2003 Scania Polska S.A. sold in Poland 30 of them, while in 2008 the company broke a record, having sold 100 ones. According to market analysts, despite the economic crisis in the automotive business, in Q1 2009 Scania was recognized as the vice-leader of the Polish exports, as it had exported 222 buses, mainly to Great Britain, Sweden and Estonia. Moreover, the Słupsk plant, is the only bus manufacturer in Poland, exporting chassis and bodies to the Russian market. In Poland most of Scania buses are driven in Warsaw, Cracow, Stargard Gdański, Opole and Słupsk.
Buses with class
Scania buses and coaches are renowned for their outstanding operating economy. As stressed by Scania representatives, the buses are relatively expensive but the purchase is going to pay off in the future, since the vehicles are cheap to exploit. Each component is carefully engineered so as to heighten the performance of the vehicle and set worldclass standards for fuel economy, driveability, road handling and reliability. Every model can be customised to ensure that the customer gets the best solution possible. The production process of the first buses assembled in Słupsk included welding the parts made of stainless steel and painting them at the end of the process. This strategy was followed by a revolutionary approach, consisting in using aluminum and bolting the elements, which entailed more changes in the production process. The series 5, currently manufactured in Słupsk, is available in 12-, 18-, as well as 13,7, 14,6-, 12,7-metres versions. One can also find double-deckers, including the ones with a steering wheel on the right hand side. The production of doubledeckers posed a great challenge for the engineers in Słupsk. Now, having manufactured more than 500 ones, they excel at the double-decker model. The year
Automotive IndustryScania Production Słupsk Księga1.indb 19
2007 was an important breakthrough in the introduction of new assortment, because the plant launched new lines for the production of the intercity bus Omniline, the series 5 10,9 m, double-decker city bus, and the ethanol-powered bus. Moreover, EURO 5 engines, which set te rigorous emission standards were introduced. All Scania buses are perfected on a regular basis, which is why they stand out in the market also in terms of passenger capacity or comfort level.
Swedish philosophy which bears fruit
The source of success of the brand in Poland can be discerned in the corporate philosophy of Scania, which is steadily implemented throughout the sales and service network. Core elements of the philosophy include the focus on the customer, whose needs are prioritized at all cost, support and respect for all employees and the elimination of all possible waste. The ability to combine those elements helps to assume leadership in the industry. The company has already been granted the quality management ISO 9001 certificate and the ISO 14001 certificate, which concerns the environmental management. The certificates serve as a proof of high quality of the manufactured goods but also as a factor motivating to keep it up. When it comes to the concern for the environment, the plant takes up numerous ecological initiatives. For example, one can enumerate the costly investment in the technology purifying the air, which hasn’t translated into the increase in earnings. Scania Production Słupsk S.A. has been granted numerous awards and distinctions which attest its reliability, honesty, high quality, concern for people and the environment. The most prestigious ones are Silver Bear - Leader in Promotion of the Słupsk Economy (Srebrny Niedźwiedź - Lider Promocji Słupskiej Gospodarki), Solid Employer of Pomerania (Solidny Pracodawca Pomorza), the Business Gazelle, Clients’ Laurels, The Exceptionally Mother-Friendly Company (Firma Nieprzeciętnie Przyjazna Matkom), Solid Entrepreneur (Solidny Przedsiębiorca). Moreover, for the last four years the award committee of the economic-consumer program Solid Company (Solidna Firma) has been giving the company a certificate attesting the business reliability, which is of paramount importance for Swedes, who treat it as one of the flagship characteristics of their working culture. To emphasize that point, Scania
Manufacturing-Journal | 17 | 2010-04-28 14:53:03
Astromal • glass and polyester laminates for everyone • from concept to production Polyester-glass laminates find practically unlimited applications. The laminates are low in weight and highly resistant both to mechanic damages and corrosion. The parts manufactured by Astromal company are the model example. Even though the company, on the market since 1980, specializes in designing and production of polyester-glass parts for vehicles of the public transport (buses and coaches, special vehicles, trams, rail buses, underground railways, passenger trains), among the customers of Astromal there are also companies from other sectors, such as medicine, advertising, mining, agriculture and others. Thus continuous development of the company provides its customers with high quality products along with comprehensive service. Many projects are created based on the company own know-how. The company has its own inventions and patents protecting industrial property rights of the company. Company strategy relies on building and maintaining the recognition of Astromal brand. Once the family company, established 30 years ago, Astromal have been transformed into a company employing over 200 people. A tight team takes all efforts to make the name Astromal well-known for its solidity, innovativeness, professionalism, honesty and top quality. The company has its own design and engineering office. This is where our specialists put into use state-of-the-art computer tools (i.a. 3D design techniques) to develop documentation and designs which are later used to produce moulds and models. Preparation of models and moulds is an indispensable phase in the production process of polyester-glass parts (GRP-GFK-PWS ). Our modern five-axle processing centre CNC makes it possible to perform very complex models in wood and in plastic (PUR), keeping the strictest quality parameters. Versatility of that appliance mated with qualified engineering personnel and professional engineering facilities allow rendering of services at the highest level, as well as meeting of all requirements and expectations of our customers. Astromal employs a number of production methods. Production of laminates is cost-effective both in short series (hand lay-up), and in medium and long series production (processing by PRESSING, FORMING,VACUUM and RTM). To address the increasing interest of customers in lighter
and lighter details, the company introduced the PWSPUR „light and foamed laminates” technology . That technology allows production of parts with weight reduced by as much as 35 % and all other technical parameters (i.a. strength, flammability, etc.) unaffected. Astromal has an optical system for measuring of parts by way of 3D scanning. The system assists operations of design department and allows monitoring of parameters of produced details (dimensions, shape, position, adaptation). The optical system also supports reverse engineering. In the result of scanning we obtain a „cloud” of points, which helps to restore the shape of a detail and then to mill it with the use of the machine - CNC Centre. Astromal is also producing parts for rail vehicles - trams and trains - such as parts of external body, interior lining, cupolas, casings, panels, partition walls, toilets, etc., as well as passenger seats and driver seats. The products meet sector standards, both European and international, and they have respective certificates and admissions. The company is also modernizing old means of transport – it offers design and upgrade of e.g. trams over 20-30 years old. The vehicles receive new, modern „look”. The company collaborates with a number of research and development institutions on development and implementation of new technologies. In addition to process modifications the company also introduces new products – polyester-glass lining and tailor-made passenger seats with improved strength properties, resistant to vandalism, a solution of choice for public transport. Innovations can also be seen in design area. Each project is approached from different perspective, so as to provide the customer with optimum solution and matching process. Astromal production process is environmentally friendly. This applies not only to the production process of laminates but also to painting of products, since the company has state-of-the-art ecological paint shop. The company is committed to meeting environmental standards. The opinion that processing of plastics causes the high risk of contamination still persists. Astromal operations contradict that stereotype. It is evidenced by certificates confirming the functioning of Integrated Quality and Environment Management System base don EN ISO 9001:2000 and ISO 14001:2004.
Astromal Sp. z o.o. ul. Graniczna 7, Wilkowice, 64-115 Święciechowa, Poland tel. +48 65 529 91 91, fax +48 65 529 78 88 info@astromal.pl www.astromal.pl
Księga1.indb 20
2010-04-28 14:53:05
Księga1.indb 21
2010-04-28 14:53:07
Subscribe for free Digital version of Manufacturing Journal | 20 | Manufacturing-Journal Księga1.indb 22
Automotive IndustryScania Production Słupsk 2010-04-28 14:53:13
has been taking part in the program promoting „Fair Play Companies.” As for the quality of particular Scania products, among the recent company’s trophies there is the QI (Quality International) title for the OmniCity bus. The plant takes pride of the model also because it also environmentally-friendly, which brought the company another distinction – in the contest Our Bests in Pomerania (Nasze Dobre z Pomorza). The ethanol-powered bus can be noticed in the roads of Uppsala, Stockholm, Råstad, Őstersund and many more Swedish cities, as well as in the cities of Norway, Italy, Great Britain, Belgium, Spain, the Czech Republic, Poland-Słupsk and even China, where they appeared at the end of 2008. As claimed by Vice Plant Manager, Sylwester Wojewódzki, the key to success of Scania Production Słupsk S.A. was also the teamwork philosophy, employees’ devotion to work and constant staff trainings. Since the employees constitute the strategic potential of the company, Scania is willing to repay them as much as it can. It strives to ensure the staff world-class conditions and it attaches particular significance to the health promotion activities, which additionally led to victory in the contest ProHealth Organization. The employees have access to medical specialists and are encouraged to take up some sport or give up smoking. It all helps to ensure higher performance, efficiency and greater job satisfaction.=
aged to shake off. Owing to the effective cost reduction, Scania was able to take an advantage of the situation and now the management of the company is optimistic about the future and ready to face new challenges. The plant is to be reorganized and modernized, which is aimed at doubling the production capacity to reach 2000 buses per year. Mr Wojewódzki comments on the company’s plans in the following way: “We set new trends in efficiency. The market, including the Polish one, is becoming more and more demanding. The users value reduction is the fuel consumption, long lifespan of the vehicle and its more efficient handling. We need to meet these challenges. (…) The future of the plant will be characterized by the search of new technological solutions and the use of alternative fuels. We are already preparing to introduce hybrid propelled buses. (…) Our brand will be always associated with an ecological approach to the product, high quality and recognizable stylistics.” It is also worth mentioning that in order to attract customers and strengthen the position of Scania in the Polish market, Scania Polska S.A. strives to extend the service network, so that the clients can be easily provided with assistance no matter where they are. Written by Anna Chudzik
Resisting the crisis
Although the economic crisis, which made Scania reduce employment, did not leave the company intact, it man-
Automotive IndustryScania Production Słupsk Księga1.indb 23
Manufacturing-Journal | 21 | 2010-04-28 14:53:15
S TI CL E AR
LIGHT TRAILERS FOR EVERYONE
FACT BOX FULL NAME: SORELPOL Sp. z o.o. PRESIDENT: Francois Feuillet OPERATIONS: Automotive ESTABLISHED: 1992 EMPLOYEES: 130
www.sorelpol.com
T
hanks to continuous improvement of products, application of modern technologies and support of French partners, Sorelpol – a company specializing in the production of trailers for passenger cars – has become one of the largest manufacturers of its type in Poland. Proper management and adequate investment decision brought the company to a point where its annual production includes several thousand of trailers. What is more, majority of the manufactures are exported to foreign countries. Written by Aleksandra Strojek
Development and outlook for the future
The establishment of the company dates back to the end of 1990. What the company focused on at the very beginning of its business operations, was development of production capacity. The goal was reached, what allowed the enterprise to significantly extend its production plant. The reconstruction took place in the year 2000 and just one year later Sorelpol launched its products on the Polish market. At the current moment Sorelpol is part of a French group Trigano, which includes various companies from eight countries, among them United Kingdom, Germany, Italy and Spain. The business of Trigano is organized around two families of products: leisure vehicles (motor caravans, cara-
| 22 | Manufacturing-Journal Księga1.indb 24
vans, mobile homes and accessories) and leisure equipment (trailers, camping equipment and garden equipment). Sorelpol and its manufactures represent the second product group of Trigano. Affiliation with the international leader is undoubtedly one of the strategic potentials of the company. Trigano’s strong brand portfolio, solid financial structure and organisation based on independent business units covering the whole of Europe, make it and its member companies key players in the markets they represent. Furthermore, they allow for an in-depth knowledge of various European markets. Future growth of Sorelpol lies also in its extended know-how and state-of-the-art technical infrastructure. The ambition of the company is to maintain the leader position on the market
of trailers manufacturing. In order to achieve this goal, the company wants to incessantly adapt its product portfolio to the needs of the customers as well as to keep up with their quality and price expectations. Other priorities are to strengthen Sorelpol’s position on the European markets, extend its technical potential as well as deepen the knowledge of the manufacturing process.
Light trailers, spare parts…
In Poland the trailers of Sorelpol are sold under the brand Neptun and Duuo. All manufactures of Neptun and Duuo brand have been officially certified by the Polish Ministry of Infrastructure. Due to that, it is possible to register them right after their purchase, with-
Automotive IndustrySorelpol 2010-04-28 14:53:17
WITAL Ludwik Witczak
REFLEKS REFLECTOR
Company “WITAL” was founded in 1987. From the beginning of our activity we have specialized in the production of reflective devices. The reflecting elements are made using our own, welltested technology, which allow our products to achieve the highest quality. All of our products have E 20 European certificate. We use very modern, high - tech equipment such as injectors and ultrasonic plastic welding machines fully controlled by computers. Professionalism of our employees as well as their experience and job stabilization are additional elements helping to keep the quality of our products. We have quality control system ISO 9001:2000. We are cooperating with biggest trailer and farm equipment producers. We provide our customers with fast and punctual realization of all orders, we also guarantee fixed cooperation contract prices.
WITAL Ludwik Witczak ul. Rezedowa 5 04-232 Warszawa wital@wital.pl www.wital.pl
We are inviting for the cooperation!
Automotive IndustrySorelpol Księga1.indb 25
Manufacturing-Journal | 23 | 2010-04-28 14:53:19
•
clamp. Thanks to the application of sliding tow bar and real panel, the length of the cargo compartment may be regulated from 3.5 to 5.5 m, Trailwood series – universal trailers for carrying various types of cargo, with ladder rack and side rails.
Majority of the above mentioned series are available in various models. They differ in the maximum gross weight and payload, the external dimensions as well as the dimensions of the internal box, number of axles or size of tyres. Next to that, Sorelpol’s trailers are equipped with a number of innovative and functional solutions, e.g. torsional axis suspension and option of vertical storage of the trailer. out the necessity of additional technical examinations. The enterprise provides constant availability and wide selection of spare parts to all of its trailers. Sorelpol’s light cargo trailer offer includes the following categories: •
•
•
City series – designed for carrying various types of cargo, recommended for city traffic, with openable rear sides, rubber rollers absorbing shocks while driving and lights built into rear panel, which guarantee protection against mechanical damage, Pratik series – adequate for carrying various types of cargo, with floor made of waterproof plywood with antislip layer, holders protecting cargo against moving about during haulage as well as six function lights built into rear panel, Uni series – which give the users enhanced functionality, with floor
•
•
•
•
made of zinc-coated metal plate, tilting open load-carrying body allowing unloading of cargo with no need to release towing hook and openable front and rear sides, Pro series – characterized by enhanced functionality and durability, suitable for heavy duty operation, with the possibility to dismantle all sides and use the trailer as a platform, Multi series – due to ramps facilitating going onto and leaving the platform by a vehicle, this series of trailers is appropriate for carrying gardening equipment and smaller vehicles like quads, Moto series – designed for motorcycle lovers, with rails and holders allowing fastening and protection of the motorcycle, Navy series – designed for carrying boats, equipped with 2 regulated side-supports, easily dismantable rear panel and a jockey wheel with a
…and accessories
Next to the light trailers offer, Sorelpol delivers to its customers a wide range of accessories that allow to adapt each Neptun trailer to clients’ individual needs, thus increasing its applications. The most popular accessories of Sorelpol include: • • • • • • • • •
universal trailer-based luggage compartment, flat canvas cover, canvas cover with supporting structure, jockey wheel, spare wheel, side extension framework, spare wheel side holder, trailer top, wire mesh trailer top.
The retail sale of trailers, accessories and spare parts is carried out exclusively via authorised distributors. As their list is rather extended, it is not difficult to find one in the neighbourbood.
Quality is in the brand
At the current moment Neptun light trailers are the most important product of the company. The wide offer of the brand allows the enterprise not only to participate but also to dominate in most market segments. In fact, the company wants to be associated with the Neptun brand and is assured that the brand stands for good quality at reasonable price. Reasons behind the acknowledgement of the customers and the popularity of Sorelpol’s products include wide availability of the manufactures. It derives from partnership-
| 24 | Manufacturing-Journal Księga1.indb 26
Automotive IndustrySorelpol 2010-04-28 14:53:25
based cooperation with the contractors, quick reaction to the changing requirements and needs of the clientele as well as top-quality post-sale service.
A look on HR and
environment policy
To keep up with rapid growth and face new challenges, Sorelpol pays a lot of attention to its human capital and employment policy. It allows the company to surround itself with the best professionals in all the areas in which it is involved. Nowadays, the company employs around 130 people and intends to increase this figure along with growing demand for its products. Due to involvement of the company in an international venture, the enterprise possesses branches in various parts of the world. It gives the employees of Sorelpol the possibility of developing their skills according to international standards. It is also an opportunity to exchange experience with colleagues from abroad. Solid organization of the enterprise and its stable financial situation mean safety and continuity of employment for those who identify with the company and engage in its undertakings. Effective cooperation with trade unions as well as direct relations between the management board and the personnel cause that the work atmosphere is fine and contacts between individual employees are based on mutual respect and willingness to help. The other area in which the enterprise does fine, is environment. Nature conservation and respect for the environment are among the fundamental values which form Sorelpol’s corporate culture. It is necessary to mention
that these values are inextricably bound up with the business activity of the company and its offer, which includes products for outdoor leisure. The ecological policy of the company is based on reduction of waste and its appropriate utilization. Furthermore, the company is in active cooperation with the local municipal authorities and together with its business partners works on the development of new, more environmentally friendly production methods. A part of those actions and undertakings results from growing legal requirements in the area of environment. The solid basis of the company together with its dynamic development figures and care for natural surrounding have been perceived by Puls Biznesu, a prestigious Polish daily. The newspaper distinguished Sorelpol in its competition Gazele Biznesu (Business Gazelles) for solid and hon-
Automotive IndustrySorelpol Księga1.indb 27
est relations with contractors as well as dynamic growth and financial results.
Economy favours the plans
The last five years have been very favourable for Sorelpol and other companies of its trade. Within that time, the Polish market of light trailers has been showing an upward trend in the sales figures. It has been connected with a general wellbeing of the economy. A crucial novelty has been the occurrence of new market players, i.e. large retail chains, and the development of new market segments which have not existed before. The company managed to face those challenges thanks to incessant market monitoring and quick adaptation to the changes in customers’ needs and distribution methods. Since the economic outlooks for Sorelpol are fine and its characteristics allow for growth, the plans of the enterprise include further expansion. First and foremost the company wants to develop cooperation with retail chains of the most significant European markets. It will result in doubling the production capacity in the upcoming years.
Manufacturing-Journal | 25 | 2010-04-28 14:53:29
S TI CL E AR
A RECOGNIZED PROFESSIONALISM
FACT BOX FULL NAME: SEGU Polska Sp. z o. o. PRESIDENT: Joachim Próba, Rufin Duda OPERATIONS: Automotive ESTABLISHED: 1998 EMPLOYEES: 420 REVENUE: 60 mln PLN
www.segupolska.com.pl
D
uring these difficult times of global financial crisis most companies struggle hard to remain its’ position in the market. It is relatively uncommon to find a company that despite the slowdown keeps going forward and expands it’s activity. This is however the case of Segu Poland, a Polish company specializing in ABS wires and wire harnesses for the automotive industry which has recently scored an impressive deal with PSA Peugeot Citroen through one of its partner, Bosch.
Segu Poland - the beginnings
The roots of Segu Poland go back to 1998 when an arrangement was signed by the newly founded company and its strategic partner – Germany based Segu Systemelektrik. The agreement regarded a supply of ABS wires that steadily started to erect a developing company and as a matter of fact still generates a majority of the firm’s sales revenue. Next came the diversification of the production; by expanding its offer with engine wire harnesses Segu Poland joined the wire manufacturer’s premier league. At first, the company’s headquarters was based in Dabrowa Gornicza, but its activity outgrew its square meters, hence the board of directors made a strate-
| 26 | Manufacturing-Journal Księga1.indb 28
gic decision to built a new factory in Sosonowiec. The new plant is located inside the Katowice special economic zone which allows the company to benefit from special tax reliefs. Moreover, the company takes advantage of the European Union’s aid funds which continue to increase its investment capital.
The evolution of the company
Constant growth is one of significant features of Segu Poland. Back in 1998, the company’s turnover equaled merely 1 million Zlotys. Not even ten years later it reached 90 millions. This rapid increase can be explained by the firm’s struggle to maintain the highest quality of offered products which resulted
in scoring new contracts yearly, while expanding the existing ones. This fact is also reflected in the company’s payroll. In the beginnings of the company, Segu Poland was hiring just 23 employees. Nowadays its profits are worked out by over 400 people. The company has also come a long way from its first factory in Dabrowa Gornicza. The current modern facilities in Sosonowiec are 10 thousand square meters packed with stateof-the-art technology. 47 hundreds of these square meters are dedicated to the wire harnesses workshop, 17 hundreds to the ABS wiring workshop and 24 hundreds are a high bay warehouse. The facilities also include a modern technical architecture, an integrated IT system designed to support the ERP management solutions as well as spacious administrative offices. In 2007, the company has terminated its relocation from Dabrowa Gornicza and now operates only form Sosnowiec. The pace of the development of Segu Poland does not seem to slow down, hence the firm
Automotive IndustrySegu Polska 2010-04-28 14:53:34
is operated by Polish wires. ABS sensor lines and engine wire harnesses are the ones that directly come to mind, but mirror wiring, headlights wiring, the airbag ignition cable, flashers, trailer set, electronic construction units and components for the air conditioning systems – all of the above are offered by Segu Poland.
Key customers and their credit
isn’t done investing in it’s infrastructure. The firm is constantly trying to renew its equipment found in its machine park, by purchasing devices form world leading companies such as Komax, Arburg or Schunk.
Main fields of activity
As said before, Segu Poland manufactures mostly ABS wires and wire harnesses. The automotive industry is the company’s main customer, not the only one however. Wires from Sosnowiec are frequently used also in agricultural and construction machines. Nevertheless, most of its products can still be found inside of an automobile. One would be truly surprised how many parts of a car
Many sector leading enterprises can be found among customers of Segu Poland. Audi and Volkswagen are on that list, however these companies are not the major partners for Segu. About 45 percent of total turnover is generated by Bosch who orders ABS wire harnesses for its systems used in automotive brand like Ford, Fiat, Toyota or Opel. 35 percent of revenue is made by collaboration with Deutz, a German company manufacturing diesel engines for Volvo. Another important customer is Siemens, for whom Segu Poland produces wire harnesses for fuel supplier systems. Both Bosch and Deutz have granted an acclaiming award for the level of professionalism in cooperation with Segu Poland. These are however not the only recognition Segu Poland has been awarded recently. The company has been honored by the city of Dabrowa Gornicza a title of the entrepreneur of the year twice, and has been accepted into a prestigious club of Business Gazelles awarded by an editorial staff of Polish business magazine “Business Pulse”, back in 1995.
The collaboration with Fiat Powertrain
Technology
Recently, the company has started business talks with another very important customer, the Fiat Powertrain Technology, commonly known as FPT. The company is a part of the Fiat Group and is responsible for designing and manufacturing of, broadly Company offer: speaking, powertain and transmisInternational transport (European Union) sion systems, both The production and trade in second hand palettes in Poland and abroud for the Fiat ComTrade in used camping trailers and motorbikes pany itself, as well Wholesale and retail trade in oils only in domestic market as for third party. Due to aforementioned experience in producing wire harnesses directly for car producer F.H.U. NEW-TON Nitoń Grzegorz (the WV collaboraPL 41-219 Sosnowiec | Ul Lubelska 13 lok 21 tion in 2004-2008), Fax: +48/32/760-90-29 | mail: newton@vp.pl matching techni-
Automotive IndustrySegu Polska Księga1.indb 29
Manufacturing-Journal | 27 | 2010-04-28 14:53:39
cal requirements of the project and the proximity of the FPT factory, Segu Poland turned out to be a perfect partner for the FPT production. 10 people were dedicated specifically to design needed harnesses while additional software was introduced to the company exclusively for the needs of FPT. The commitment made to the new projects and to it’s customers’ needs are what stand out as a key factor in the firm’s success on the market.
Research and development
In order to expand their abilities to produce wires and wire harnesses, Segu Poland cooperates with several scientific and research units, including the Institute of Welding in Gliwice. Recently said collaboration resulted in developing two technological processes jointing copper wires with copper plates in two welding technologies – resistance and ultrasonic. This is a major step for the company, as the welding process is becoming more and more important technology in jointing metals and Segu Poland is gradually becoming an expert in said matter. The company constantly increases the volume of investment in its research and development department, since it’s well aware of the value of the firm’s innovation. Modern technologies help bring new contracts to the company which allows the company to keep its leading position on the market, even during these difficult times.
The production of wire harnesses
– step by step
One might found interesting the production process at Segu Poland. First, we start with cutting and crimping with the fully automated system Komax Alpha. Each and every crimp is thoroughly measured and controlled. Then we move on to ultrasonic welding. All parameters of each splice are being examined on the spot. The splices are insulated with glue shrink tubes, which are gas and liquid resistant. The part moves to a dedicated assembly table, where it’s being assembled and label, but only if the control results are 100% error free. Then a part is tested in various ways, in-
cluding extreme temperature tests, temperature shocks, salt tests, pull out force of crimps and many more. Segu Poland leaves no place for an error in its production process and this obsessive attention to details is what leaves its customers satisfied.
The philosophy behind the product
Even the best technology is not enough if it isn’t managed properly. And at Segu Poland, the management puts in a lot of effort to make sure that the work of their finest engineers is not in vain. The CEO’s has introduced an ERP Pro Alpha system to all of its departments. The firm operates on lean management standards and uses a cooperative style of management. Teamwork is also one of key words when it comes to describing work at Segu Poland, both in the office and at the workshops. All of this to ensure that the extraordinary talents working on a top notch equipment release the highest quality products. This policy seems to work perfectly well, as the company’s evolution doesn’t seem to have reached its final phase. Written by Łukasz Światowiec
| 28 | Manufacturing-Journal Księga1.indb 30
Automotive IndustrySegu Polska 2010-04-28 14:53:43
S TI CL E AR
FULL NAME: Magneti Marelli PRESIDENT: Adriano Fontana OPERATIONS: Automotive ESTABLISHED: 1992 (in Poland) EMPLOYEES: 4910 TURNOVER: 2.776 mln PLN
Production plant Automotive Lighting Polska Sp. z o.o. operating in Sosnowiec
M
AGNETI MARELLI is a leader on international market of designing and production of components and high-tech systems for automotive industry. In Poland it has 5 production plants which have been developing on the local market as well as for export for over 18 years.
Italian history of the company
The company Magneti Marelli (the name of the company comes from the surname of Italian enterpreneur Ercole Marelli) was founded in Italy in 1919 as a joint venture of Fiat Torino and Ercole Marelli & Co. The company started to operate on the market by launching one component – magneto (from which comes the 1st part of company’s name) – designed for automotive and aeronautical industry. Afterwards the enterprise entered the market of domestic appliances. In 70-ties the company diversified its production, dividing the offer into specialised production. It was a good response to the needs of demanding international market. In 90-ties Magneti Marelli chose the strategy of developing its main business and core products: components for automotive industry.
History of Magneti Marelli in Poland
In Poland Magneti Marelli was founded in 1992, when the factory FSM was purchased by Italian group – Fiat. At the beginning the plants of Magneti Marelli produced automotive components for one principal client – Fiat Auto Poland. At the end of 90-ties the production policy: many different components produced by using many different technologies for one client was changed. There were made some investments in order to increase efficiency and to maintain profitability in comparison with raising competition. In Poland the production was rationalised: less components of one type were produced using specialised technology and were directed to more clients. At present the activity of Magneti Marelli in Poland includes 5 specialised business lines: •
• •
Automotive Lighting Polska in Sosnowiec (lighting components for cars – components of headlights and car lamps) Magneti Marelli Exhaust Systems Polska also in Sosnowiec (components for exhaust systems) Magneti Marelli Suspension
Automotive IndustryMagneti Marelli Księga1.indb 31
www.magnetimarelli.com
•
Systems Bielsko in Bielsko Biała (shock absorbers and suspension systems) Plastic Components and Modules (two production plant in Sosnowiec, production of bumpers, dashboards, internal and external parts of car equipment and fuel tanks made of plastics).
Customers’ confidence
The Magneti Marelli group cooperates with many automotive concerns – apart from Fiat: the Volkswagen group, Toyota, Opel, Audi, Ford, Citroen, Mitsubishi and Hyundai. In this context the Italian history of the company is particularly important. The Magneti Marelli is regarded as a trustworthy partner – this position was elaborated due to the process of company’s specialisation. In the industrial history of Magneti Marelli scientific research has always been playing a main role. Thanks to it, the enterprise maintained high technological quality. It is prestigious that before the second world war the general director of Laboratories of Scientific Research of Magneti Marelli was Enrico Fermi (a worldwide known scientist). Since the beginning of Magneti Marelli’s existence, which lately has celebrated its 90th anniversary, its trademark remains unchanged. It con-
INTERNATIONAL LEADER OF HIGH-TECH SYSTEMS FOR AUTOMOTIVE INDUSTRY
FACT BOX
Manufacturing-Journal | 29 | 2010-04-28 14:53:44
POTENTIAL AND EXPERIENCE AURES Ltd. since 1996 year is running company, of continuous development, experience in the automotive industry. The company specializes in the production of highly advanced technological parts made of thermo-plastic. It also specializes in assembling products which require high technical knowledge and a vast array of specialized machinery. AURES Ltd. covers an area of 24,000 m2. The company’s production plants and warehouses cover an area of over 7,000 m2. It employs more than 140 highly qualified employees. LOCATION AURES company has its registered office, production plants and logistic facilities in a place which is attractive due to its proximity to the most important transport routes in the south of Poland and due to a direct neighborhood of the resilient and the biggest in the country industrial area – 15 km away from Tychy(Fiat Plant) and Katowice, 45 km away from Bielsko Biała and 45 km from Gliwice (Opel Plant).
QUALITY SYSTEM In June 2009 AURES Ltd. obtained certificate proving the coherence of an existing Quality Management System with ISO 9001:2008 requirements and the technical specifications included in ISO/TS 16949:2002.
Aures Sp z o.o. ul. Mikołajczyka 50 41-200 Sosnowiec, Poland phone: +48 32 750 08 42 fax: +48 32 297 63 21 e-mail: aures@aures.pl www.aures.pl
| 30 | Manufacturing-Journal Księga1.indb 32
OUR CLIENTS: MAGNETI MARELLI GROUP: AUTOMOTIVE LIGHTING and PLASTIC COMPONENTS AND MODULES (formerly ERSI) as well as HUTCHINSON, TRELLEBORG, RETTIG HEATING, SCHOELLER ARCA SYSTEMS, PROSEAT, LYS FUSION.
plastic processing
electric wire
quality system
lamp assembly
Automotive IndustryMagneti Marelli 2010-04-28 14:53:47
Expert in the field of cellular products
www.tekspol.com.pl
Tekspol Sp. z o.o. ul. Żeliwna 43 40-852 Katowice tel. +48 (0) 32 2590 481 fax +48 (0) 32 2590 482 e-mail: biuro@tekspol.com.pl
Tekspol Sp. z o.o. (part of Tekspan Automotive Group) was founded in 2003 in Katowice, and is a highly specialized company in development and fabrication of cellular products, for industrial, automotive, packaging and other branches applications. Our main applications and products are: Die-cut and laminated gaskets Extruded and die-cut profiles Technical Packaging Soundproofing installations Antivibrating pads
Tekspol Sp. z o.o. ul. Żeliwna 43 40-852 Katowice tel. +48 (0) 32 2590 481 fax +48 (0) 32 2590 482 e-mail: biuro@tekspol.com.pl www.tekspol.com.pl
Among very wide range of our materials - the most representative and provided are: EPDM – extruded EPDM - compact NBR SBR SBR+NR Silicon Polyethylene foams Polyurethane foams Many others As a branch and business specialists we’re able not only produce goods according to drawing of our customers but also we are flexible to help to find proper solution of problem – starting from choosing material, through production and logistic.
Automotive IndustryMagneti Marelli Księga1.indb 33
Manufacturing-Journal | 31 | 2010-04-28 14:53:49
firms a huge capital of this brand and shows that it is well recognizable.
Poland’s strategic potential
Production plant of Magneti Marelli Exhaust Systems Polska Sp. z o.o. operating in Sosnowiec.
Production plant of Plastic Components and Modules Poland S.A. operating in Sosnowiec
Production plant of Magneti Marelli Suspension Systems being in Bielsko-Biała
The strategic potential of Magneti Marelli in Poland is caused by many factors as: advanced and innovative technological solutions as well as full service in all phases of product’s life: design, production and service of spare parts. The strategic potential is also caused by the fact that Polish group belongs to a wider industrial reality and has opportunities to use innovative solutions implemented at a global level of the whole group. It can also exchange knowledge and know-how with all European parts of the group. As a consequence of development in Poland, the group created the department of implementation of new solutions (Application Centre) for the Divisione Lighting, which employ 40 Polish engineers. They gained professional experience in France, Germany and Italy. At a global level the group invests about 4,5 % of its turnover in worldwide scientific research. Magneti Marelli in Poland is still developing – one of its long-term plans – a project of a new production plant is supposed to become an European pole in production of shock absorbers. Also the location of already existing Polish production plants is very important: near the key supplier and other specialised suppliers. The recent trends of global economy allow to expect the growth of sales in the countries of Eastern Europe. While planning the strategy of development, the company has to take into consideration also environmental requirements, that is why innovative ecological products will have key impact on competition on the market in the future. Opportunities of Polish production plants: qualified engineers, collaboration with universities of technology, highly specialised workforce show that the company is well prepared for future.
HR policy Interiors of a production plant of Automotive Lighting Polska Sp. z o.o.
| 32 | Manufacturing-Journal Księga1.indb 34
Magneti Marelli group in Poland counts 4910 FTE. The enterprise is an appreciated employer because it offers a secure workplace in one of the biggest industrial groups in the region. It is important especially nowadays
when the job is not stable. HR policy of the company in Poland is based on trainings, promotions and bonuses for the most promising employees. It provides the personalized training courses and systems of professional evaluation. For many years the company has maintained a low index of employees’ rotation. A very important part of HR policy is a pursuit to make all employees (physical worker like operators of injection moulding machines as well as supervisors) realise the role of their position and their work for the results of the whole group. In order to increase employees’ involvement last year the company started to implement the programme World Class Manufacturing and made a lot of trainings. In November the company completed the first WCM audit, necessary to achieve the proficiency level.
Products – market
The group describes its strategy in the following way: „to implement the mission of being a supplier of components for automotive industry at a global level, Magneti Marelli chooses quality and being competitive, advanced technology and flexibility, having as aim to make key technologies accessible at reasonable prices for the final user.” Years before the crisis: 2005, 2006 and 2007 witnessed an intense growth. Increase of production value allowed expansion and considerable investments. There were built two new production halls, of the surface of more than 25.000 m2, new production lines were launched and a new business line – Ergom Automotive – specialised in plastic components was purchased. However, the scale of financial crisis was so big that only a few enterprises were not affected. Of course last winter also Magneti Marelli had to face the recession on the market, but it managed to overcome it quickly at the beginning of this year thanks to better juncture and incentives which had positive influence on the sales of its main client. Currently, when the markets recover stability, the enterprise hopes to continue its growth. During last 5 years Poland changed considerably. After the crisis it became an economical leader of Eastern Europe. As one
Automotive IndustryMagneti Marelli 2010-04-28 14:53:54
Control panel produced at the Plastic Components and Modules S.A. plant in Sosnowiec
of a few European countries Poland managed to avoid the recession and maintain positive economic growth, thanks to its geographical position and strong internal demand. Poland attracted many international industrial groups, and not banks as in Baltic countries. Poland created appropriate infrastructure in order to attract new investments. It brought only a few immediate benefits but it contributed considerably to long-term growth. Besides, Poland – as one of the most numerous countries of UE – offers access to well-qualified human resources: physical workers and engineers. At the same time the economical growth created the medium class, which is able to stimulate the economy by strong internal demand, which few years ago would not have been possible.
to find new contacts with suppliers, which in future can substitute European countries in this matter. Magneti Marelli is proud of the fact that is has played an important role in the history of Polish industry, in the region and whole country by offering workplace and opportunities of career to young Poles. The group hopes to continue its success in Poland and in other countries. A motto, which the company would like to pass on to the readers of Manufacturing Journal is the following: it is worth planning, producing and selling innovative products of high quality because only in this way the integrity of enterprises’ economies at national and European level can be saved in confrontation with emerging markets. Written by Berenika Wilczyńska
Exportation strategy
The recent economic crisis touched also Magneti Marelli and brought a slight slowing down. However, it didn’t cause serious problems thanks to wideness of Magneti Marelli’s offer, which is designed for many clients. The majority of production of Magneti Marelli in Poland is designed for export. Nowadays in the age of globalization, when economies of different countries are related, the export is particularly important. The fact that Italian headquarters invests in development in Poland means that our country plays a strategic role for future company’s growth. In this context the role of emerging markets is important. Increase of exported quantities will depend on ability to enter new markets and maintain with them economic relations. Italian headquarters invest also in China, India and Brasil. The fact that Polish production plants belong to this industrial world is a chance
Lamp for the model Audi B8 produced at the Automotive Lighting Poland plant in Sosnowiec
ELGUM AUTOMOTIVE Sp. z o.o. since 1994 is a long experienced company dealing in production and distribution of: rubber elastomer products for automotive domestic appliance industry www.elgumautomotive.pl
Automotive IndustryMagneti Marelli Księga1.indb 35
Our products have been certified by ISO 9001:2000 and ISO-TS. ELGUM AUTOMOTIVE Sp. z o.o. Ul. Schönów 1A 41-200 SOSNOWIEC Tel./fax: + 48 32 363 10 35, 36 elgum.automotive@ea-elgum.com
Manufacturing-Journal | 33 | 2010-04-28 14:53:59
S TI CL E AR
WORKING WITH THE GIANTS
FACT BOX FULL NAME: Fabryka Osprzętu Samochodowego „Polmo” Łódź S.A. PRESIDENT: Tomasz Węglarczyk OPERATIONS: Automotive ESTABLISHED: 1908 EMPLOYEES: 249 (2008) REVENUE: 15,8 mln Euro (2008)
www.polmo-lodz.com.pl
F
or over 40 years FOS „Polmo” Łódź S.A. has been the biggest compressor producer in Poland. The company has been manufacturing automotive equipment and accessories since 1929 and its establishment goes back to the beginnings of the 20th century. In the past, the enterprise would supply the whole automotive industry in Poland. At the current moment, its geographical scope of operations is much bigger. Thanks to the development of cooperation with foreign customers, most of Polmo Łódź production is exported. Written by Aleksandra Strojek
100+ years of tradition
The company was established in 1908 and no more than twenty years later, in 1929, it started the production of car accessories. After the World War II had been finished, the enterprise experienced some ownership changes. It was namely nationalized and transformed into a state-owned company. The next years witnessed extension of the product offer. The company took to manufacturing of carburetors for cars and motorcycles, developed motor S03 for the legendary Junak motorcycle and in 1956 released carburetors, fuel pumps and stationary motors of its own design. In the second half of 1960ies it also managed to receive Weber license for carburetors, Corona license for fuel pumps and Westinghouse license for compressors. In
| 34 | Manufacturing-Journal Księga1.indb 36
1974 Polmo Łódź developed compressors, carburetors and pumps for FIAT.
Ownership and structural changes
The political and economic transition in Poland brought about many changes to the business activity of Polmo Łódź. In 1995 the enterprise changed its legal form again. After the privatization process, it stopped being a state property and became a privately owned joint stock company. As far as the legal issues are concerned, at the moment the main stockholders of Polmo Łódź are members of the management, employees and other natural persons. Right after ownership changes, the company decided to confirm the top quality of its products and in 1997 it introduced the ISO 9001 certificate. The year 2002 witnessed significant structural and organizational transformations. The enterprise separated its core activity – production of compressors – from the manufacturing of carburetors, fuel pumps and air compressor units. In 2003 ISO 9001:2000 was introduced and just one year later, in 2004, a new manufacture appeared on the product portfolio of Polmo Łódź. The company started the production of housings for turbochargers.
Cooperation with the giants
Thanks to the license received from We-
stinghouse as well as development of its own constructions, Polmo Łódź managed to acquire extensive know-how and competence in the area of compressors and their parts production. Until today, compressors with the enterprise’s logo are a synonym of a reliable, top quality product. The professionalism and knowledge of Polmo Łódź were the reason behind close cooperation with the most important market players of the automotive industry – Knorr-Bremse, Haldex, Borg Warner Turbo System or Wabco. It shall be mentioned here that at the current moment Wabco (previously: Westinghouse) is the key customer of Polmo Łódź. The cooperation has been going on since 1968, when Polmo Łódź purchased license from Westinghouse. Next to Wabco, another giant of the trade and a direct competitor, which also located its orders at Polmo, is Knorr-Bremse.
State-of-the-art machine park
Close cooperation with foreign partners, modern manufactures’ constructions as well as concentration on the quality cause that the company incessantly invests into its machine park. In this respect the enterprise has been taking advantage of the European Union funds. The co-financing of the investments started still before Poland’s accession to the organization. At the time, the subsidies came from the pre-acces-
Auotmotive IndustryPolmo Łódź 2010-04-28 14:54:03
high requirements of foreign customers. The machine park of the company consists among others of the following CNC machines: vertical and horizontal machining centres, lathes, grinding machines, drilling, polishing and honing machines as well as many others. A supplement to the machine park are hardening furnaces and a furnace for plasma nitrification. Polmo Łódź is one of the very few companies in Poland which are equipped with the latter facility.
Product portfolio
At the current moment the product offer of Polmo Łódź includes: •
•
sion programs PHARE. At the moment, Polmo is involved mainly in the Sectoral Operational Programs dedicated among others to small and medium sized companies. The funds have been used to purchase new machines as well as to equip the enterprise’s measurement la-
boratory. Owing to this ventures, Polmo can boast of a modern machine park which mainly consists of CNC machine tools. These machine tools assure repeatability and proper quality of the produced manufactures. The machine park was built in such a way that it meets the
• • •
single cylinder or two cylinder piston compressors for pneumatic brake system, available in various types and varying with respect to cylinder diameters, total piston displacement, stroke, type of lubrication, cooling and working pressure characteristics, etc., compressor parts (mass components production for compressor assembly as well as spare parts for aftermarket), designing and composing of the pneumatic brake systems for tractors, turbocharger housings, couplings for pneumatic brake systems.
Except for that, new machinery and modern measurement base let Polmo machine such parts as: • • • •
crankshafts made of steel forgings and cast iron castings, cast iron and aluminum housings, valve plates cooled by air and water, cast iron cylinders – Plateau.
What is more, taking into consideration its compressor production know-how, Polmo started to design and complete the air brake systems applied in such tractors as: Farmtrac, Farmer and URSUS.
Awards in a number of areas
The high quality of the products, reliable and partnership based business contacts as well as dynamic growth of the financial figures resulted in a number of distinctions from various organizations and in diversified competitions. The distinguished areas of the enterprise’s business activity have been among others: exports, innovation, sales dyna-
Auotmotive IndustryPolmo Łódź Księga1.indb 37
Manufacturing-Journal | 35 | 2010-04-28 14:54:06
mics, relations with the employees and many others. The list of awards and prizes is then long and includes: the title of Gazela Biznesu 2005 (Business Gazelle), received from a prestigious Polish newspaper Puls Biznesu; nomination to the title of Solidny Pracodawca 2006 (Solid Employer) or the title of Supplier of the Year 2004. The latter came from a French company Knorr-Bremse.
Impressive sales figures
positive effects for FOS Polmo Łódź, it has also influenced the company in the negative sense. It refers mainly to the recent financial crisis, which badly affected the automotive trade. The crisis reduced the production of the company by around 20-30%. In order to face the challenge, at the beginning of 2009 the company implemented a complex restructuring program. Its main goal was to adapt the company and its ventures to the new market situation and unfavourable economic indicators. An intensive cost-cutting and restructuring program allowed the company to overcome the worst six months. Next to that, new production process (aluminum parts) was introduced. The management of the company has also done a lot to start cooperation with new customers. In order to convince them to the producer from Łódź, the enterprise elaborated for them absolutely new compressors and their parts or modernized the old ones. The company is also proud that it managed to retain the best specialists and experienced professionals at its premises. It means that once the economy is back on the good track, Polmo Łódź will be able to quickly react to the growing demand coming from the customers.
What future holds
The strategy of FOS Polmo Łódź S.A. for the nearest future is first and foremost to strengthen the position of the company as the significant producer of the components for the automotive industry. This goal is to be achieved by further investments in new technology and modernisation of the machine park and equipment as well as extending the customer base and product diversification. The latter means introduction of new products applied in passenger car sector. The company is aware that the production level and sales figures will not quickly return to the values from the peak years. Yet, even the smallest upward trend in the business of the producer’s customers will allow Polmo Łódź to continue with the renewal of the machine park and carry out some investments in this area.
As mentioned before, for some time Polmo would supply almost the whole of the Polish automotive market. The structural as well as ownership changes, which took place at the beginning of 1990ies and concerned the majority of state-owned companies, resulted in their acquisition by foreign corporations. As the latter would start their own production, Polmo Łódź lost a significant share of its market. What helped the enterprise to overcome the hardships, was cooperation with foreign companies, for which Polmo Łódź manufactured compressor parts, first and foremost crankshafts and housings. Since the time, the cooperation has been deepened and extended by a number of new clients. Quickly developing market, a number of investments as well as relations with companies from the OEM market resulted in sales value of 15,8 mln euro in 2008. The scale of this figure is emphasized when one compares it with Polmo’s financial results from the year 2002. At the time, the enterprise’s sales leveled to 5,3 mln euro.
Turbulent market
Despite the fact that cooperation with the largest market players has had many
| 36 | Manufacturing-Journal Księga1.indb 38
Auotmotive IndustryPolmo Łódź 2010-04-28 14:54:09
AR
TI CL E
S
THE MOST ECOLOGICAL BRAND IN EUROPE
FACT BOX FULL NAME: Fiat Auto Poland S.A. PRESIDENT: Enrico Pavoni OPERATIONS: Automotive ESTABLISHED: 1992 EMPLOYEES: 6422 REVENUE: 19,55 bln PLN
Factory of Fiat Auto Poland in Tychy
F
iat Auto Poland was established in 1992, but it has made its presence felt on the Polish market for 89 years. Longstanding experience has obligated the company to maintain professional service and high quality of the vehicles. Its dynamic development depends on innovative technology solutions ensuring driver and passenger comfort. The Tychy Factory, the largest automobile factory in Poland, the biggest Fiat factory in Europe and the second in the world after the Brazilian one.
Brief history
Trees with strong root systems can withstand any violent storm and grow high. Decades old tradition of the Italian automotive giant, FIAT, which is a historically recognized brand, and the quality of Polish Fiat Auto Poland go hand in hand. The popularity and success of Fiat are a result of building a good rapport with customers for years. The history of one of the carmaker forerunner in Europe started when the founding act of Fabbrica Italiana Automobili Torino was signed on 11 July, 1899. Giovanni Agnelli became a managing director then, and it was his dynamic personality and resourcefulness, which shaped the characteristic style and influenced the quality of future products. The first factory was opened at Corso Dante in Turin, in 1900. Before Turin became a home for the flourishing automobile industry, it
www.fap.pl was famous for the Shroud of Turin kept pany was renewed in 1971, when the in the Cathedral of St. John the Baptist. contract was signed to produce a small Two other important plants built in later car, Fiat 126, in Poland. The selection years were Lingotto, with a futuristic test was based on the simple design and track on its roof and Mirafiori, where cut- cheap maintenance of the car, which ting edge technology solutions were was supposed to be available for an avused. The latter was particularly impor- erage Polish citizen. (wykreślone zdanie) tant for Polish male citizens in 70s and The privatization process of FSM (small80s, who boosted their sense of self-re- car factory) started in 1990. As a result, spect by owning an inevitable attribute three joint-stock companies emerged of success and professional position, two years later, namely, Fiat Auto PoFiat 131 Mirafiori, whose name derived land S. A., Teksid Poland S. A. and Magfrom the Turin factory. The car model neti Marelli S. A., which specialised in gained extreme popularity, but prior car, foundry and automotive compoto this craze, the cooperation between nent sectors. A new stage in the proFIAT and Poland, did not always pro- duction of Fiat in Poland was sealed by ceed smoothly because of the political the production of Cinquecento, a new inconvenience and economic crisis. Dur- model enthusiastically embraced by ing the pre-war period, Polski Fiat was a customers. Fiat Auto Poland took over thriving company, which specialized in FSM and reorganized the methods of the production of Fiat Topolino, whose management, work ethics and the qualItalian nickname means Mickey Mouse, ity of cars, which became a top priority and Fiat 508, so called Balilla or 4’ door for the company. Poland reinforced its carriage, which earned customers’ trust as the best family car. However, the WWII stopped the The most modern car body stamping press in Poland winning streak, Top quality products guaranteed by innovative technologies the factory was destroyed and its re c o n s t r u c t i o n was stretched over a long peGESTAMP Polska tel.: +48 61 436 96 00 riod of time. The ul. Działkowców 12 e-mail: gestamp@pl.gestamp.com cooperation with 62-300 Września, Poland www.gestamp.com the Italian com-
Since already 5 years
together we „press” the future
Auotmotive IndustryFiat Auto Poland Księga1.indb 39
Manufacturing-Journal | 37 | 2010-04-28 14:54:14
ORSA-MOTO Sp. z o.o. ORSA-MOTO Sp. z o.o. is a medium-sized company. It was established in the Łódź Special Economic Zone in Ozorków in 2002. Since that time, it has been one of the fastest developing and the most dynamic suppliers of parts and components in the automotive sector in Poland and on Central European markets. The managment of ORSA-MOTO makes use of all possibilities created by the location in the economic zone in order to achieve aggressive development objectives, i.e. competitive labour costs, easy access to highly qualified specialists. The capital connection with the Italian group Orsa s.r.l. makes close cooperation of research departments possible, aimed at constant development of new technologies and simultaneous extension of the products range. Owing to the above-named factors, we are becoming one of the main and the most competitive suppliers of needle punched nonwoovens and pressed details for the automotive sector. Our main recipients are, among others, Fiat Auto Poland – Panda, Ford Motor Company – Mondeo, GM – Opel Agila, Chevrolet AVEO, Suzuki – Splash, FSO – Lanos, ADLER Polska, Johnson Controls.
ORSA-MOTO Sp. z .o.o. DUNS No. 422418231 ul. Adamówek 37 95-035 Ozorków PL tel. +48 (42) 270 01 00 fax. +48 (42) 718 91 32
www.orsamoto.pl
ozorkow@orsamoto.pl
PRO-CARS | Podleska 16 | 43-100 Tychy | POLAND Tel 48 32 782 80 00 | Fax 48 32 782 80 11 procars@procars.com.pl | www.procars.com.pl Steel stamped parts Aluminium heat shields for exhaust systems
PRO-CARS The PRO-CARS Company specializes in the production of steel and aluminum pressed parts and cars’ subassemblies produced in technology of pressing and welding. Our offer contains parts such as steel and aluminum heat shields for exhaust system, engine and chassis supports, spring seats, metal parts for wiper arms, brake pedals and oil pans. The technologically advanced machine park includes progressive presses of tonnage pressure up to 800 Tonnes, pneumatic and mechanical presses of tonnage pressure up to 500 Tonnes, devices for welding of the power up to 160 kVa and devices for assembling compound details. Having nearly twenty years of experience and motivated employees with high technical skills, and modern infrastructure PRO-CARS is able to meet all quality standards and requirements in the automotive industry. PRO-CARS cooperate with internationally recognized brands like: Fiat Group Automobiles, Audi, BMW, GM Opel, Magneti Marelli, Tenneco Automotive, Isuzu Polska, Valeo, Delphi.
| 38 | Manufacturing-Journal Księga1.indb 40
Auotmotive IndustryFiat Auto Poland 2010-04-28 14:54:18
The company PROTECH IT IS: highest quality service, trained staff – highly professional staff comprising machine operators and installers, reliable and professional execution of orders, as the only company in Poland we have specialist equipment to dismantle, relocation and installation of heavy machinery and equipment at low production halls, competitive prices and the possibility of negotiations and very good references from our clients.
Equipment depot: Crane model 44A up to 400 tons Lifts from 25 to 200 tons Platforms for the transport of heavy machines Electric and combustion forklift trucks FTL transport PROTECH ul. Kosciuszki 25 34-326 Pietrzykowice Polska tel. 0048(0)33 47 50 367 tel/fax 0048(0)33 47 50 369
Księga1.indb 41
Protech Motors Deutschland Westheck 28, 59427 Unna Deutschland deutschland@protech-motors.com Tel: 0049-157 81 622 633 Fax: 0049-2303 999 276
We specialize in the following areas: • • • • • • • • • • • • • • • •
Crane Services Relocation of industrial plants Dismantling and assembling machinery and equipment Transport of machines at home and abroad Installation of ventilation systems Disposal of equipment Manufacture and assembly of steel structures Sequences of Technology Welding sockets Roller conveyors Hand Specialist Special pallets for the transport of elements between plants Upgrading of technological lines Industrial installations Lifting Equipment Machining
Equipment base: ul. Przyległa 36 43-300 Bielsko Biała Poland
www.protech-motors.com 2010-04-28 14:54:20
Shower of awards
position as a producer and controller of car assembly of small and large cars, Fiat Uno, Punto, Siena, Bravo, Brava, Marea, Ducato, Seicento, Palio Weekend, New Fiat Panda and Fiat 500 (also for Abarth company), to name but a few. FAP became also an exclusive importer of Lancia, Alfa Romeo and Abarth to Poland. As a result of an agreement between FIAT Group and Ford Motor Company in 2008, Poland was to produce a next-generation Ford Ka and Fiat 500. It was a challenge, which stimulated the development of the company and strengthened its leading position as the largest foreign investor and exporter in Poland. The foreign sales of cars produced in Tychy accounts for 3% of Polish exports and is a pride of the Polish automobile industry. Fiat Auto Poland S.A. produced a record-breaking number of cars in Tychy in 2009, i. e. 605 797, which is an improvement of 112 912 cars more than in 2008 (around /+ 22,9%).
Export hit and polish symbol
of the 70s
Fiat 126p was consistently driving Syrena models out of business and became a long-awaited car for Polish drivers. Also foreign users took an instant liking to a cute and small Fiat 126p, nicknamed ‘maluch’. The car was exported to more than 30 countries, mainly to former Federal Republic of Germany, France and Great Britain, but also to Cuba, India and Australia. During 28 years, the design of small Fiat was improved and modified so that it would be more ecofriendly, less noisy and more convenient for physically challenged people. New models of Fiat were represented by Fiat 126p Face Lifting, featuring the system of a turn-key ignition, Fiat 126p Bis with the third rear door and watercooled engine, Fiat 126 el with electronic ignition and without triangular windows and finally Fiat 126 elx Maluch with a catalytic converter. The last line of Maluch, available in yellow and red colour, was produced on September 22, 2000 and was named ‘Happy End Baby’.
Fiat 500
| 40 | Manufacturing-Journal Księga1.indb 42
FIAT received a great number of accolades in the category of management, eco policy and quality of its vehicles. The most important are: • ISO 9001 Quality Assurance Certificate in 1996; • ISO 14001 Environmental Management System certification for the Body Plant in Tychy in 1999; • ISO 9001:2000 and PN-N-18001 in 2002; • The Polish Quality Award in 2004; • FAP was recognized for excellence in 2005 in the European Quality Award Competition and it was the first awarded Polish company in this competition; • Bronze Level Award for adherence to WCM standards in 2007; • The top place for Fiat Panda in the category of city cars in ADAC’s 2008 reliability ranking; • ‘Auto Lider 2008’ special award for FAP for its long-standing contribution to the development of Polish automotive industry and economy; • Silver Level Award in 2009 from the WCM audit; • BEST CARS 2009 award for Fiat 500; • The first place for Fiat 500 in the reader poll ‘The Best Cars of 2009’ in the category of the smallest cars organized by a German magazine Auto Motor und Sport. The car won in 12 out of 17 countries, where the competition was announced; • Car of the Year for Fiat Panda in 2004 and Fiat 500 in 2008.
‘Improving the environment
is not a goal for the future, but something we can do right away...’
Along the lines of environmental protection and continuously increasing fuel prices, companies follow the strategy of sustainable development to win customers’ trust. FIAT Group, as the bestmanaged company, entered the prestigious stock market indexes DJSI World and DJSI STOXX, with a score of 90/100 compared with an average of 72/100 for all companies in the same sector. DJSI scrutinizes various indicators from three aspects, economic, social and environmental, according to the concept of sustainable development, which is a long-term goal for FIAT Group. Using new technologically-advanced engines, which reduce fume emission consider-
Auotmotive IndustryFiat Auto Poland 2010-04-28 14:54:26
ably is a key success indicator for FIAT. The company decreased carbon dioxide emissions to 129,1 g/km, which complies with the European requirements for 2015. Therefore, it is a leader among the brands, such as, Toyota, Peugeot, Citroen, Renault, Ford, Opel, Volkswagen, Audi or Mercedes. (wykreślona część zdania) Natural Power, which are bio power engines, take credit for these outstanding results. The MultiAir Technology is one of Fiat’s innovative solutions. The benefits of MultiAir engines are increase in power up to 10%, 10% reduction in fuel consumption and CO2 emissions, 60% reduction in NOx emissions, 40% reduction in HC/CO and enhancement in its operational flexibility. The new class of remarkable diesel engines, 1.6 and 2.0 Multijet is the second and improved generation of Common Rail diesel engines. Multijet system is a breakthrough in diesel technology as it provides multi-stage injection cycle of 3 to 8 openings during the final phase of power stroke and exhaust stroke, which ensures less combustion noise, reduction of exhaust emissions and improvement of parameters. Its high quality provides 35 000 km service intervals, which reduces vehicle maintenance cost. Furthermore, they meet the recent Euro 5 regulations for motor cars considering the emission of the ozone precursors and dust particles. Fiat Bravo is one of the first models which was equipped with Multijet 2.0 with DPF, which reduces the exhaust fumes considerably. Start&Stop systems, which are used by a large number of Fiat vehicles, ensure fuel efficiency, reduce exhaust pipe emissions and guarantee low cost of production. They operate by automatically turning off the engine during
idling and starting it after releasing the clutch pedal. Impressive hands-free system Blue&Me, which was invented in the cooperation with Microsoft, enables a driver to use a mobile phone by giving voice commands. It has to be emphasized that the high-tech device does not have to be taught to recognize the timbre of a driver’s voice. Blue&Me system was integrated into various models of FIAT Group, whose users can take advantage of eco:Drive application, which monitors a customer’s style of driving and its influence on fuel consumption and fume emission. They can also be advised on how to modify their style of driving to lessen the exhaust fumes. Eco:Drive system is supposed to reduce the emissions of CO2 up to 15% and economize on fuel up to 120-200 euro. The programme can be downloaded for free from the official FAP website. FIAT is an unquestionable leader in the production of compact and eco-friendly cars. It offers two new products, namely, the LPG range of panda, Grande Punto and Bravo with bio-power engines and PURO2 line of Fiat 500, Croma and Bravo, with Start&Stop system and eco:Drive application, which will reduce fuel consumption, ecological tyres, less viscous oils, aerodynamic packages and longer ratio gearbox. Downsizing of gasoline engines is simultaneously introduced, as it leads to larger production of small-car segment, which provide plenty of power and have low combustion rates. The tendency to choose smaller cars over the larger ones is growing, as the former are easier to afford, cheaper to maintain and fuel efficient. Written by Karolina Burkiewicz
Fiat Panda MY 2009
Auotmotive IndustryFiat Auto Poland Księga1.indb 43
Manufacturing-Journal | 41 | 2010-04-28 14:54:29
S TI CL E AR
HOW TO INVEST IN STYLE
FACT BOX FULL NAME: Simoldes Plasticos Polska Sp. z o.o. PLANT MANAGER: Rui Tavares GENERAL MANAGER: Mr. Jaime Sá OPERATIONS: Automotive ESTABLISHED: 2003 EMPLOYEES: 325 REVENUE: 26 Mln €
www.simoldes.com
C
heck if the components of your car’s interior fit-out have a Simoldes Plasticos logo. If so you are Plant Manager lucky because - Mr. Rui Tavares this label guarantees top notch quality. The company is well established in Portugal, Brazil and France and enjoys recognition among the automotive brands such as: Porsche, Toyota, Peugeot, Citroen, Volkswagen and Skoda. Simoldes Plasticos has been present in Poland since 2004, its headquarters located in JelczLaskowice near Wrocław, Lower Silesia.
in their footsteps. They placed their new branch in Poland and over time it proved a perfect choice. Strategically located between East and West, the country offered enormous potential in terms of economy. The recent global crisis further confirmed the resilience of the Polish fi-
nancial system. Simoldes Plasticos entered Poland in 2003. Initially, in order to check if the Polish market is worth giving a go, the company registered its office in Warsaw. The business put down roots here a year later when they launched an investment in Jelcz-Lasko-
Injection Technology Comes to Poland
Simoldes Plasticos, which nowadays enjoys the status of the largest mould manufacturer in Europe, was set up as Simoldes Aços on 30th November 1959. For the first 25 years the business specialised in mould processing and after that it continued operating in yet another strategic direction. The vibrant Injection Division joined the already mentioned Mould Division. In 2004, when the EU started admitting new members, automotive industry entered the area of Central and Eastern Europe and the Simoldes Plasticos management followed
| 42 | Manufacturing-Journal Księga1.indb 44
Automotive IndustrySimoldes Plasticos 2010-04-28 14:54:35
wice near Wrocław. No one expected it would soon develop into a factory which employs more than 300 people. There were some teething troubles of course but the business came to grips with it by 2006. That year the company turned over a new leaf with a comprehensive management reform which soon turned out to be a landmark for the whole Simoldes Group. Integrated corporate procedures were at once introduced at all the plants in Portugal, Brazil, France and Poland. These rules relied heavily on 5S formula which was created by Japanese managers and whose elements included: sorting, setting in order, shining, standardising and sustaining discipline. This made it possible to facilitate the cooperation between the branches which were finally made into a network. As Mr. Rui Tavares, A Plant Manager in JelczLaskowice, says: “We share the same vision, the same strategy and conform to the same standards. As a team we are able to achieve more than ever before.”
Model Management
From the strategic point of view it was the Continuous Improvement Process that mostly contributed to the success of Simoldes. “We want to get better every day,” says Mr. Tavares, “This motto will give you a picture of what our business is all about.” The CIP blueprint is put into practice in many ways, a few of which to be found below. There are key performance indicators together with Bulletin Board System which allows administrative officers to share their computer data via common network. The business carries on seeking for new friendly technologies and innovative materials. With a view to quality improvement the company has launched Quality Function Deployment System which gives boost to cost management and facilitated lead-time reduction. This scheme also allows to cut back on common materials and reduce contingent dangers. At Simoldes Plasticos they take pride in their Project System which has accelerated the pace of investment and rationalised its costs. Consequently, every undertaking to be given a try is thoroughly appraised in terms of money involved, alternative solutions and potential return. Last but not least, it should me remarked that separate improvement teams focus on internal project portfolio management, stock reduction, productivity and material cost saving.
Trust and commitment
The Simoldes Plasticos mission has been defined as follows: “To be preferred choice for our customers, employees and suppliers, to contribute to a sustainable growth and satisfy our shareholders.” For this reason all the advanced management tools have been created with the aim of customer satisfaction. At Simoldes Plasticos they know how to meet the demand of their clientele and take proper care of production and services quality. Hence their corporate motto: “Deliver our commitments and trust in each other.” It goes without saying that the company attaches great importance to prospective profit. Nonetheless, as they hold to the principles of integrity, reliability and sustainability, they also set store by the ways of money making. The company tends to foresee market trends as well as potential trouble. Their managers are aware of the fact that it is always better to anticipate and avert problems rather than to solve them. For that matter the Simoldes strategy is prepared for at least 4 years in advance, which allows to steer away from undesired difficulties. Mr. Tavares sums it up as follows: “We require that our workers are proactive, resolved and flexible. Our staff makes it sure that the quality of products and services delivered reflects these criteria.
Top of the Range Manufactures
Simoldes Plasticos can be surely counted among those who broke new ground in terms of injected moulds for automotive industry. Their plants in Portugal, Brazil, France and Poland prove able to meet the global demand of these goods. Since 2000 the business has kept increasing annual turnover which is nowadays reaching figures around 260 mln EUR. Hence the decision to expand further and create a branch in Poland, which specialises in turning out interior trims, trunk trims, door panels, wheel arch liners and front-end carriers. The last of these are particularly popular, which has so far brought sales of 9 mln EUR a year and promises dynamic growth in the years to come. The majority of products manufactured in JelczLaskowice is exported to the Central and Eastern European countries such as Germany, Slovakia and Czech Republic, the rest is marketed in Poland. The reliability of the manufactures has been further confirmed by the fact that this plant has won numerous prizes and
Automotive IndustrySimoldes Plasticos Księga1.indb 45
Manufacturing-Journal | 43 | 2010-04-28 14:54:42
been granted quality certificates such as ISO 9001, QS 9000, ISO TS 16949. In the near future this list will be appended by yet another, namely ISO 14000 awarded to those businesses which are keen to preserve the environment.
Proactive and Motivated
A leader in the Polish mould industry, Simoldes Plasticos has so far created more than 300 jobs. As Mr. Tavares stresses: “Our staff in encouraged to actively participate in the daily life of our company. We require that our future should be kept in mind by our workers.” This principle is put into practice in many ways. Firstly, the company has come up with and applied the idea of a suggestion system which, being employee oriented, gives the staff an opportunity to put forward independent thoughts and then play a conscious part in the decision making process. Thus, they take action the way the experts would, identifying the problem and then implementing solutions. The management lends support to their efforts, which results in the levels of morale and motivation being increased. Secondly, for the benefit of the workers and the plant alike a number of interdisciplinary improvement teams have been set up. The business keeps investing heavily in training programmes for the staff who are thus enabled to broaden their technical expertise and acquire soft skills necessary for cooperating with others. As Mr. Tavares puts it: “We believe very strongly that the funds
| 44 | Manufacturing-Journal Księga1.indb 46
spent on professional training pay off rather quickly. That is why in 2009 and 2010 we are going to put 1,900,000 PLN for that. As much as 60% of this figure is subsidised by the EU. The people we welcome onboard are given a chance to develop as the company develops. For that matter we tend to hire the young and talented whose initiative and potential we might put to use in the future. The onus on the management is to make the most of these rich human resources.
crisis has made labour available again on the market, the business has managed to rise to all this challenge too. People who then decided to stay onboard may now enjoy the double benefit of good pay and a work-life balance oriented career. This is how Simoldes Plasticos envisage their HR policy for the years to come. Written by Bartosz Sowiński
Challenges Faced so Far
The Polish branch of Simoldes Plasticos may prove a perfect example of how successfully and properly do business in Poland. Nonetheless, the company was not always that prosperous. The major challenge the business has faced so far arose at the very beginning of its activity. In the area there were virtually no other companies from the same industry to tie bonds with . There were no people either whose skills would make it possible to employ them without necessary training. The factory had to educate staff at first. They carried it off thanks to the support of the mother company from Portugal who secured a series of interior and exterior training sessions. The hard times came also in the years 2006-2007. This turbulent period meant cut-throat competition for workers who then massively migrated to Ireland and the UK. This brought about employment turnover and consequently the increase in the costs of labour. Since the recent financial
Automotive IndustrySimoldes Plasticos 2010-04-28 14:54:51
AR
TI CL E
S
BRIGHT LIGHTS, BRIGHT FUTURE
FACT BOX FULL NAME: TRUCK-LITE EUROPE Sp. z o.o. MANAGING DIRECTOR: Mikołaj Konieczny OPERATIONS: Automotive parts supplier ESTABLISHED: 2000 EMPLOYEES: 140 PENSKE GROUP REVENUE: 18 bln USD (for 2006)
www.truck-lite.pl
I
f you have a car, it is highly probable that your vehicle is fitted with a klaxon and lamps Tomasz Wojciechowski manufac tured Sales Manager by TRUCK-LITE Truck-Lite Europe Sp. z. o.o. and you are not even aware of that. This text will help you to do necessary catching up. Located in Bydgoszcz, northern Poland, the company has proved a reliable provider of signal horns and lighting and thus commanded the respect of automotive boffins. Although established in Poland less than ten years ago, the brand has managed so far to achieve recognition on every continent. They have traded with all the most powerful businesses including the leaders of the industry from Germany, United States and Japan. Written by Bartosz Sowiński
Auspicious Start
Short nonetheless abundant in landmark events, the history of the TRUCK-LITE activity in Poland provides a detailed illustration of the market there. The Polish economy underwent a process of globalization as soon as many local businesses faced the prospect of cut-throat free market competition and started cooperating closely with foreign investors. Hence the inception of TRUCK-LITE in Poland, which initially
operated under the FER-Belma Sp. z o.o (LLP) brand name. It came about in 2000 in Bydgoszcz thanks to the joint venture of Polish and German capital, namely B.Z.E. BELMA S.A. and FER Fahrzeugelektrik GmbH. The founders , each of which boasted a few decades of trading experience and contacts with VW, Audi, Seat, Porsche, MAN, and FIAT Auto Poland, set out to create a centre for acoustics in Central East Europe. Owing to the cutting edge technology, highly qualified staff and quality management FER Belma soon got the project off the ground and joined the leaders of the global automotive industry. Mr. Tomasz Wojciechwoski, sales manager at TRUCK-LITE elaborates on it: “Then we proceeded to establishing liaison with the partners in Korea (GM DAT), China (Shanghai GM) and Japan (FUSO Truck and ISUZU). However, it is two events that followed which set a strategic course for the company’s development. In 2002 FER Fahrzeugelektrik GmbH entered into a close alliance with American Penske Group which took over majority shares in it and thus gained control over its foreign branches too. Soon after that, in 2004, they went into partnership with TRUCK-LITE (belonging to Penske Group), the leading provider of lighting for the heavy duty industry in the US. Subsequently, the investors from TRUCK-LITE decided to buy the shares of B.Z.E. BELMA S.A. from FER-Belma.
Auotmotive IndustryTruck Lite Europe Księga1.indb 47
Corporate Network
As a result of its founders’ structural conversion the Polish branch of TRUCK-LITE enjoys a rare opportunity to rely on capital assets of no fewer than four corporate businesses – FER Fahrzeugelekrik GmbH (now TRUCK-LITE EUROPE GMBH), Flexible Lamps Ltd (now TRUCK-LITE EUROPE LTD, Harlow, UK), TRUCK_LITE US and Penske Group. “The combined power of these companies makes a springboard for us establishing a status of a strong and reliable partner for European entrepreneurship,” Mr. Wojciechowski adds. The first of these, located in Eisenach, Germany, and established in 1907, FER Fahrzeugelekrik GmbH boasts the annual turnover of 75 mln EURO. They began as a modest manufacturer of carbide bicycle lamps and over time specialised in turning out elements of vehicle wiring and lighting. Nowadays, due to long-term partnerships with Bosh and Volkswagen, to name but a few, the company enjoys recognition of the most prominent worldwide car producers. The second of these, Flexible Lamps Ltd. was set up in 1924 in London. Since the inception it has been focused on manufacturing lighting for commercial vehicles, mainly for lorries and trailers. They also focus on rubber sealed lighting, hence the brand Rubbolite. The third, established in 1955 in America, TRUCK_LITE has a turnover of up to 473 mln USD per annum. Its infrastructure
Manufacturing-Journal | 45 | 2010-04-28 14:54:52
includes 13 factory floors in the US, UK, Germany, Belarus and China. The rate of employment there reaches 3,000 workers who serve more 4,000 clients with 24,000 distribution locations. It proved successful on the strength of its patent portfolio and a variety of affordable and environment friendly solutions. Suffice it to say that TRUCK-LITE belongs to an elite of producers taking advantage of energy saving LED lighting. Finally, the third corporation, namely Penske Group, being a dominant stakeholder in both FER Fahrzeugelekrik GmbH and TRUCK-LITE, prides itself on a truly global range. Set up in 1965, it has created more than 34,000 jobs so far in the US, Mexico and Europe and reached the rate of 18 bln USD (for 2006) of annual turnover. Penske Corporation boasts also an enormous fleet of around 220,000 lorries. Nonetheless, the business takes greatest pride and invests heavily in the R&D sections, which give employment to around 5 % of its entire workforce.
| 46 | Manufacturing-Journal Księga1.indb 48
Quality Recognised
Little woder, therefore, that the TRUCK-LITE branch from Bydgoszcz acts with a view to the topmost level of lighting and signal horns quality. That is why their motto reads: “The business is good only if it wants to get better.” It goes without saying it was devised for the sake of the customer satisfaction. Everything has to be spick and span there, even before components enter production lines. This allows to avoid unnecessary trouble as it often happens when solutions on offer do not meet the demand of the competitive contemporary market. Nowadays, customers favour goods that are not only economical, but also safe, clean and sustainable. In order to cater for them TRUCK-LITE in Poland made a blueprint for and launched the Integrated Quality and Environment Management System, which complies with the requirements of ISO/TS 16949: 2009 technological specification and ISO 14001 standards. It is further substantiated by the relevant certificates which confirm that the company is able
to satisfy the exacting quality requirements in terms of the whole production process, including design, manufacturing proper, installation and distribution alike. The process itself is seen to by a representative of the Quality and Environment Management System Board, who is responsible for: specifying quality aims and policy; popularization and development of the consciousness in terms of our customers demands and expectations amongst the employees; supervising the administration; planning and controlling audits; obtaining quality certificates; and cooperation with customers and suppliers. This hard work did not pass unnoticed in the industry. FORD awarding the Q1 status on the Polish branch of TRUCK-LITE proves a case in point here. This department was also invited to join an elite club of “Polski Panteon Ekologii” (“Polish Ecological Pantheon”). People at the company regard it as a crowning achievement on their narrow path to sustainability. Mr Wojciechowski also stresses the fact that in 2007 the company received the NCAGE code (NATO Commercial and Government Entity) for the businesses vital in terms of national defence.
Know-how and Cutting Edge Gears
As such the Quality and Environment Management System Board takes care of necessary supervision and research. This team conducts thorough verification already at the stage materials and components supply. Thanks to automatic objective solutions these guys not only attest the quality of ready products for sale, but also carry out spot checks at random stage of the production process. Each phase is monitored with the equipment which guarantees the necessary accuracy of the measurements taken. These gears are calibrated
Auotmotive IndustryTruck Lite Europe 2010-04-28 14:54:55
and monitored by expert contractors. Periodical audit assessment and requalifying research is in turn done in the TRUCK-LITE laboratory. The products which were complained about are also analysed there. Owing to the technical know-how of its workers and cutting edge technologies the laboratory is able to face such challenges as: length and angle measuring using the VISION measuring microscope, type HAWK SYSTEM 7, and the 3D MITUTOYO coordinating measuring machine, type CRYSTA APEX C776; electro acoustic parameters measurement of signal horns in a semianechoic chamber with BRÜEL & KJAER gears; climatic and anti-corrosion examinations performed respectively in the WEISS TECHNIK climatic chamber, type WK-340, and in the WEISS TECHNIK salt spray corrosion chamber, type SC – 450. However, there is more to the technological capabilities of TRUCK-LITE than just the laboratory. There is also an impressive portfolio of more than 200 patents from all over the world. As we are not permitted enough space to include all these, we should at least mention sealed and shock-mounted lamps, energy saving LED lighting, new generation fuel filters and gas assisted mirrors.
Scope of Production
Let’s move on to a review of what TRUCK-LITE EUROPE is able to offer the automotive industry. The company specialises in manufacturing disc and trumpet signal horns for all types of vehicles including motorcycles, passenger cars, trucks, as well as forklifts and other heavy-duty vehicles. Mr. Wojciechowski stresses: “Our manufactures are regarded as High Value Product. For that matter we provide horns for Porsche. At the moment our annual sales figure has reached 3,000,000 items.” Each and every of basic models has at least a few
dozen variants according to specific demands of our customers concerning protective covering, assembly methods, type of connector and colour. The second main branch of the TRUCK-LITE production are lighting elements for passenger, commercial and special vehicles, including side direction indicators, interior lamps, number-plate lighting, stop lamps, control lamps. As regards special vehicles, the company complies with the requirements of the producers of trucks, trucks, buses, vans, coaches, agricultural equipment (tractors, harvesters), building equipment (bulldozers, steamrollers). They manufacture lighting exterior such as: headlights, side lamps, multifunctional rear lamps, and work lamps; as well as interior for: gauges, driver’s cabin, glove compartments and junction box. Mr. Wojciechowski drew our attention to three models in particular: firstly, a pioneer on the market, a multifunctional rear LED lamp for trailers and lorries (for pics, see next page), Model 756, which will not let you down under the conditions when other lamps stop working; secondly, a multifunctional rear lamp, Model M800, reliable even under averse weather conditions and designed so as to face reduce risk of mechanical damage; and thirdly, a new generation junction box for trailers, Model M820, which guarantees that your electric circuit will work for many years. In addition, TRUCK-LITE catalogues include a wide variety of VOLVO mirrors, class II and IV, manufactured thanks to state of the art gas assistance technology. These light and at the same time resistant mirrors were produced with a view to regulations of the EU. They were designed so as to allow maximum visibility and reduce the level of air resistance. This obviously makes you save fuel.
Auotmotive IndustryTruck Lite Europe Księga1.indb 49
Worldwide Clientele
It should be also remarked that a wide variety of solutions, spotless technology and affordable pricing made the products mentioned above grow in popularity among experts and buyers alike. Nowadays it would we easier to identify the producers which do not take advantage of the TRUCK-LITE services than those that entered contracts with the company. The list of the latter abounds in real giants. For the sake of space we can name but a few, after the first and one of the last letters of the alphabet, namely Aston Martin and Audi and Volkswagen and Volvo respectively. As Mr. Wojciechowski suggests: “Polish manufactures tend to be considered top quality. A “Made in Poland” label makes a powerful case in the course of serious negotiations, especially nowadays when all the producers have to struggle against the deluge of the Asian junk.” Only this year has the Polish branch of TRUCK-LITE gone into partnership with Daimler and MAN Latin America. The business has also launched a campaign in Kuwait, which hopefully will turn into a gateway to the thriving markets of the Near East. The TRUCK-LITE logo has managed to reach all the continents so far. That seems the best recommendation for the businessman to dream of as the facts and figures and their powers of persuasion always convince better than a mere blowing one’s horn.
Manufacturing-Journal | 47 | 2010-04-28 14:54:56
S TI CL E AR
OFFERING INTEGRATED LOGISTICS SOLUTIONS
FACT BOX FULL NAME: FESCO Transportation Group PRESIDENT: Sergey Generalov OPERATIONS: Transportation & Integrated Logistics ESTABLISHED: 1880 REVENUE: 1.246 bn (2008)
www.fesco.ru
F
ESCO Transportation Group is the largest integrated private company in Russia, providing wide range of transportation services and logistics solutions. It combines advantages of own maritime rail and motor transportation, stevedore services in own port terminals in the biggest ports of Russia and the CIS countries as well as wide net of representatives all over the world. Written by Kateryna Ferdyn Group’s business assets include various types of modern, fast and safe vessels, own park of diversificated rolling-stock, own main-line and diesel-locomotive shunters, freightliners, container equipment, water surface and on-land terminal complexes. It allows to build-up a unique intermodal chain every time when fast hi-grade cargo transportation is needed.
History of Company’s Transformation
Fesco Transportation Group is a company with almost 130-years history. Originally, being only a shipping company, with the course of time Fesco has been transformed into FESCO Transportation Group - an integrated logistics service provider selling solutions, not simply space on ships or railcars. In 2002 the current main owner of the company, Sergey Generalov, accumulated the controlling stake in FESCO. This marked the start of the new era in the company’s
| 48 | Manufacturing-Journal Księga1.indb 50
life: from a loss-making shipping enterprise with unclear management system FESCO was transformed into an efficient and profitable company, with streamlined decision-making processes, finetuned business strategy and clear strategic objectives. Next step came in 2004, when FESCO for the first time in its history came out from sea on land, creating a joint venture with the Russian Railways: the company called Russian Troyka. The idea behind this company was to create a high-tech, innovative rail arm used as an integral part of FESCO’s intermodal sea-land service. Russian Troyka, as part of FESCO, pioneered several new technologies in the Russian transportation market being the first to launch regular scheduled container trains, the first to put to industry-scale use innovative 80feet intermodal container platforms. In 2006-2007 FESCO continued its expansion on land, acquiring 100% of Russia’s second largest independent rail operator, Transgarant, with over 16,000 railcars in operation and over 25 offices across the country. Next big acquisition was a 50% interest in National Container Company – an uncontested leader in Russia’s port container handling 40% market share, operating three port terminals in Russian Baltic and Black Sea as well as in Ukraine, a dry terminal near St.-Petersburg, and developing the new Russian largest container terminal project in Ust-Luga port. Next came the acquisition of Vladivostok Commercial
Sea Port. FESCO became a 50% owner in this business. Later, FESCO consolidated 75% of Vladivostok Container Terminal – a stevedoring company operating in the port. This gave a strategic advantage of control over the port – a previously missing piece of the puzzle in the intermodal chains in the Far-East. ,Having accumulated so many assets in 2008 the company moved to a completely new management system, where all FESCO assets and companies were grouped into 4 business units: shipping, rail, terminals as well as liner and logistics. A single management company was founded, gath-
Transport and Logistics IndustryFesco 2010-04-28 14:54:58
ering all top management talent and decision making to offer to clients partnership and supply chain integration, not simply a transportation on a route. For this long period of work one thing left unchanged: values and traditions of commitment to the highest quality standards. Just like nearly 130 years ago, Fesco strives to constantly expand the range of its services, reduce delivery time and optimize the costs. The company is committed to offering modern solutions, meeting today’s challenges and contributing to the competitiveness of international and domestic clients.
FESCO Integrated Services
FESCO Company operates in four main direction: shipping, rail, terminals as well as liner and logistics. Far-Eastern Shipping Company (FESCO) PLC —a base company of FESCO Transportation Group — is Russia’s 3rd largest shipowning company and the largest nonoil cargo carrier. FESCO fleet consists of 67 vessels with total deadweight more than 900 thousand tones, operating in almost every part of the World Ocean. Today FESCO’s container lines link ports of USA (both East and West coasts), Canada, South-East Asia, Korea, Japan, China, Vietnam and North-West Europe (Baltic countries, Poland, Germany, Finland etc.) with each other and with European and Far Eastern ports of Russia. FESCO is also one of the main carriers in Far East basin of the Pacific. Company’s fleet is able to provide cargo transportation in ports with limited navigation period, including unloading operations
to non-facilitated shore. In 2006 FESCO’s fleet carried 60% of coastal and 40% of international container shipping in Far East. In addition, FESCO is the biggest operator of Russian ice-breaking fleet. Strengthened ice-classed vessels and ice-breakers can not only carry cargo, but can provide ice escorting of other vessels in hard-to-reach areas of Arctic and Antarctic. FESCO’s ice fleet supplies all-year round safe operating of oil deriving platform in Sakhalin as well as tankers escorting. All of the company’s vessels fully meet the international standards of safety and quality. In accordance with the requirements of the International Ship and Port Facility Security Code (ISPS Code), each vessel is equipped with an automatic identifica-
Transport and Logistics IndustryFesco Księga1.indb 51
tion system. FESCO containers are used for cargo transportation all over the world, providing services of maritime, railroad and motor facilities of one of the largest Russian transport holdings. Transport Group within FESCO operates more than 50 thousand TEU, including not only standard, but specialized 20-ft, 40-ft dry and reefer containers, and equipment. FESCO’s container park corresponds to present cargoflows and trade needs and provides safe and highquality delivery of almost every kind of cargo. In container segment about 70% of sales comes from imports. Trucking service has become an independent line of FESCO activity, aimed at «door-todoor» cargo delivery for short distances from Company’s cargo and logistic terminals. The trucks fleet consists of both powerful and environmentally friendly vehicles, produced by world-leading companies.Rail companies included in the FESCO group operate rolling stock, having 15 000 railcars and platforms. The Group provides international and domestic cargo transportation in own rolling stock, container transportation by regular block-trains, reefer containers regular service, forwarding services for enterprises, and other services. Rail division services are sold mainly domestically, except for the rail part of intermodal packages.Talking about share of import and export on a group level approximately 55% are foreign sales, 45% are domestic ones – under normal market conditions. Nowadays, with imports plunged, the focus is shifted on domestic clients: 35% of sales is generated from foreign clients, and 65% - domestically.
Manufacturing-Journal | 49 | 2010-04-28 14:54:59
Success Proved by Figures
2008, despite of a depressive 4th quarter, was generally a very good year for FESCO. But for the crisis it could have been much better. The consolidated revenue for the year grew more than 40% year on year to reach 1 billion 246 mln USD. The biggest drivers of this growth were growing volumes, especially in rail and liner and logistics businesses. The Group’s EBITDA for 2008 based on IFRS audited statements is USD 356 mln, or a 32% increase compared to 2007 EBITDA. This number, while still being a good growth over 2007, is however materially lower than the management accounts numbers publicly revealed earlier because of the National Container Company not consolidated in the second half of the year. Based on the management accounts, with NCC results factored in on proportional basis, the EBITDA for 2008 is USD 412 mln. According to IFRS statements, Fesco recorded USD 20 mln of net profit.
services, adjust sales network to better market and sell these services as well as offer client-oriented integrated packages. For achieving all these goals FESCO has an excellent team of profes-
sionals, working together on releasing synergies from interaction of various businesses - and this is key in the company’s business model. Currently FESCO employs over 7,000 people all around the world, including ship crews. In addition, Company’s reach and scale definitely help reach the success. While being not a very big company on a global scale, in Russia container segment FESCO is the biggest player, which gives the ability to offer services in a wide geography, increasing clients reach. FESCO has over 70 sales offices in 15 different countries in Russia, CIS, South-East Asia, Europe and the USA. Finally, FESCO offers a really unique business idea of an integrated service provider, which gives a visible competitive edge. There are no other players in Russia, with a similar access to the Russian cargo base and clientele, who would be able to provide the same spectrum of services and control the same variety of assets.
FESCO Strategic Potential
The principles of responsibility before clients, individual approach to their tasks in combination with highly professional and skilled staff and active utilization of the most up-to-date information technologies allow FESCO to provide the most reliable services of the highest quality. Integration of all business units into a seamless business model undoubtedly contributed to success. The company believes, that strategically the future clearly belongs to “onestop shop” types of service providers. So, FESCO future strategic potential is to further elaborate all these integrated
| 50 | Manufacturing-Journal Księga1.indb 52
Transport and Logistics IndustryFesco 2010-04-28 14:55:00
AR
TI CL E
S
TOP QUALITY SOLUTIONS FOR TRANSPORTATION
FACT BOX FULL NAME: CMT Chojnice Sp. z o.o.
OPERATIONS: Automotive / machine transportation
ESTABLISHED: 1991
www.cmt.com.pl
E
stablished in 1991, CMT is one of the leading manufacturers of tilt semitrailers, dump truck semitrailers, trailers, bodies for truck chassis, as well as specialised equipment, tilts and advertising materials. Thanks to the company’s determination, passion and willingness to adjust to customers’ needs, its products enjoy great popularity not only in Poland, but also on other European markets. Written by Anna Chudzik
Modest beginnings
The company was established in October 1991 in the form of a partnership and named “Chojnickie Maszyny Transportowe” Faryna, Klunder, Mięsikowski, employing only three staff members apart from the three owners. At the beginning, the company’s profile revolved around the production of machinery for the food industry, but soon after, CMT started manufacturing goods for the transportation. In November 1994 the owners bought both the land and the buildings in Chojnice, but when production exceeded the capacity of the plant, the company decided to additionally lease out premises in Brusy. The wide recognition of products, which were systematically growing in number on the domestic market, triggered off the decision to start production earmarked for export. That moment can be considered a milestone in the history of the company, and as a further boost for develop-
ment. The thriving business also resulted in the steady growth in the number of employees. What particularly came in useful for construction engineers was the implementation of the ProEngineer program, which is one of the world best integrated 3D solutions, used by manufacturers for mechanical engineering, design and manufacturing. Moreover, the company systematically enlarged its machine facilities, e.g. by putting a paint chamber or a numerically controlled plasma cutter into operation. In 2002 the company made a contribution in kind to “CMT” Chojnice Sp. z o.o. (limited liability company). Two years later a new production hall was opened, where the final assembly takes place. Yet another important year was 2005, when CMT received the ISO 9001:2000 certificate, which objectively asserts the high quality of services delivered by the company. As one can see, the company has been a major success story. Once a small enterprise with a handful of employees, CMT currently employs 130 people and has share capital of PLN 4,023,000. More than 18 years of experience resulted in top quality products and the capacity to handle even the most demanding tasks.
Trailers, semitrailers, dump trucks and more…
Over all years of activity CMT widened the range of its products successively. Nowadays the company can boast a wide array of products on offer, ranging
Automotive IndustryCMT Chojnice Księga1.indb 53
Manufacturing-Journal | 51 | 2010-04-28 14:55:02
from various kinds of semitrailers and trailers through different truck bodies, to carriers and lifts. CMT semitrailers are available in the following forms: tilt semitrailers, box semitrailers, platform semiltrailers, semitrailers with movable floors and container semitrailers. One can also find self-dumping trailers and semitralers with a rear or side dump, and various sorts of truckbodies for truck chasses of different brands. The bodies can be offered in the tilted, box, container, and self-dumping ver-
| 52 | Manufacturing-Journal Księga1.indb 54
sions (three-way or rear dumping). Selfdumping vehicles are equipped with aluminium or steel boxes of rectangular section or chute section, which are designed mainly for transportation of aggregate, gravel, or bituminous bulk. The products which have recently enjoyed the greatest popularity in the category of semitrailers are dump truck semitrailers as well as low chassis CMT NSP-24 models, which are strengthened and adapted for the transport of construction machinery, such as loaders, road
rollers, crushing machines, forklift trucks.
Quality control
From the initial stages, CMT has strived to ensure high quality of its products, especially in terms of the aesthetic appearance, exploitation parameters and durability. ISO 9001:2000 certificate asserts that the company applies a Quality Management System for designing, production, service and sale of transport devices. 3D model of products are cre-
Automotive IndustryCMT Chojnice 2010-04-28 14:55:10
ated by the team of specialized personnel in the Construction Technology section. It allows the company to eliminate any construction flaws and potential interference of the elements. Moreover, CMT carries out the durability tests, using the finite element method (FEM), which also helps to improve the process and reduce vehicle curb weight. All products are manufactured in a modern factory floor and then they undergo the shot blasting process. After that they end up in a paint shop, where they are coated in protective layers. The company puts emphasis on the control of its products, which is why, after the final assembly of components and installations, each product undergoes the technical acceptance in the Quality Control section. It serves as a guarantee for a faultless product that will correspond to the order. As for the components used in the CMT products, they belong to the top-notch companies in the world.
with a steel box, which is earmarked for the Swedish market and designed to transport bituminous bulk. The box is insulated in order to minimise the loss of heat while transporting hot bulk. Thanks to the possibility of changing the pressure on the movable truck of the semitrailer, obtained by changing the distance between the pin and the axles, it perfectly fits into the Swedish needs and regulations of the law. The hydraulic system is used in the movable truck, as well as to open the back of the truck, and also to open and close the roof, which is made of the canvas cover stretched over the steel frame. The company also strives to anticipate the clients’ needs, so it is open to any suggestions and
remarks concerning the exploitation, which would help to improve the product quality. It is also worth mentioning that CMT has been widely appreciated abroad. Its products find application not only on the domestic market, but they also reach Denmark, Sweden or Norway.
Each product is a novelty!
Since the company presents a customer-oriented approach, its objective is, within its capacity, to live up to all expectations and satisfy its customers by delivering the products they wish. All CMT products are customized to the individual needs of clients. The company accepts individual orders, which makes each and every vehicle one of its kind. The flexibility of the company, as well as the ability to accept all orders, can be exemplified by the dump truck semitrailer
Automotive IndustryCMT Chojnice Księga1.indb 55
Manufacturing-Journal | 53 | 2010-04-28 14:55:15
S TI CL E AR
EXPERIENCED IN ITALY, EFFECTIVE IN POLAND
FACT BOX FULL NAME: BITRON Poland Sp. z o.o. PRESIDENT: Sergio Damilano OPERATIONS: Domestic Appliances and Automotive Industry ESTABLISHED: 1998 EMPLOYEES: 770 REVENUE: 300 mln PLN
www.bitron.pl
B
itron Group is a privately owned, multinational company and a global leader in the field of research, development and production of mechatronic components for the appliance and automotive markets.
The company was established by Giovanni Bianco in 1955 in Turin, in the North of Italy. Since the time the enterprise has expanded Chairman of the board geographically Mr. Sergio Damilano and at the current moment it is present in a number of countries all around the world. The presence is either through an own managed manufacturing plant, a joint venture or simply a marketing and sales office. One of Bitron’s manufacturing works is located in Sosnowiec, in the industrialized Silesia region in the southern part of Poland.
Following the customers
The history of the Polish division dates back to 1998. The enterprise followed the steps of its customers, which would recognize Poland as a dynamically developing and promising market and moved there their production processes. In order to continue the long-term cooperation Bitron arrived to Poland and started to serve its customers from this country. As the company was not sure if the new location will turn to a success, at the beginning it would rent some production facilities. “The leasing” had lasted for around three years, when Bitron decided to acquire some land and start construction of its own manufacturing plant. The first product manufactured in the newly opened factory left its premises nine PRODUCER OF CORRUGATED PIPES FOR NEEDS: OF AUTOMOTIVE, DOMESTIC APPLIANCES, MEDICINES, CONSTRUCTIONS AND OTHER years ago. In 2004 the company received a license to enter the Special Economic Zone of Katowice. The administratively separate part of the Polish terri„ITIB Poland” Sp. z o.o tel.: 033 4888844 tory, designed first ul. MIĘDZYRZECZE GÓRNE 403 fax.: 033 4888842 and foremost for 43-392 Międzyrzecze Górne www.itib.com foreign investors,
| 54 | Manufacturing-Journal Księga1.indb 56
offered Bitron more favourable business environment and a number of tax privileges. It accelerated the development of the company, which resulted in opening up of a new production field in 2008. Its area reaches 56 thousand square meters out of which 50 per cent serve the production purposes. Sergio Damilano, the President of the Polish unit, claims that after more than ten years of business activity in Poland the most significant point in the corporate history seems to be the very decision to arrive to Poland. – It was a plucky step, yet it allowed us to maintain our business relations with a number of the most important market players. Due to that, the start was easier for us, we did not have to search for new cooperation possibilities, we simply continued the ones that existed previously – he says.
Two markets to serve
The company is active in two different markets. The first one is appliance, the second one – automotive. The dual orientation is visible in production volume. Around 75 per cent of the products is delivered to appliance manufacturers. The remaining 25 per cent is purchased by representatives of the automotive industry. The President of Bitron Poland emphasizes that nowadays the production proportion is changing. – It is more or less 60% to 40% for the appliance market – he says. When asked about the reason of the diversification, Mr. Damilano points to extended and long-term coop-
Domestic Appliances and Automotive IndustryBitron Poland 2010-04-28 14:55:16
eration with the customers. The Italian headquarters have been functioning according to this proportion since the establishment, so its transfer to Poland was a natural step. – We have always cooperated with a large number of producers representing the white market. We simply reacted to their requirements. It was the necessity of the market – he recalls. The list of Bitron’s main customers is impressive. In the sector of appliance it includes such giants as: Bosch, Indesit, Eudora, Whirlpool, Miele or Electrolux. In turn, cooperation with the automotive industry proceeds with such companies as: Valeo, Delphi or Denso. At this point it is worth to mention the world-wide clientele of the Bitron Group. The company has been cooperating namely with other world famous manufacturers, e.g.: Candy, Daewoo, Faber, General Electric, L.G. Electronics, Samsung, Audi, BMW, Fiat, Iveco, Lamborghini or Volvo.
At the current moment, the heating system components which can be purchased at Bitron Poland are motors for 3 way valves. Automotive industry can stock up with such products as: •
•
temperature as well as humidity and temperature sensors, detecting temperature of passenger compartment for ATC systems, operating with large accuracy and low current consumption, HVAC motorized actuators,
• • • •
various types of HVAC control panels, blower switches, de-ice switch module, rear mirror control switches.
Product offer – some details
The product portfolio of Bitron Poland is extended. Undoubtedly, the offer is dominated by manufactures for the appliance industry. The company delivers dishwasher components, elements for washing machines and components for heating systems. The offer of dishwasher components includes among others such products as: • • •
•
water softeners, removing calcium and magnesium hardness in the water used by the dishwasher, electronic timers, for both fully integrated as well as free standing machines, door switches, controlling the opening and closing of dishwasher door, available with a child safety feature, detergent and rinse dispenser.
The components for washing machines delivered by Bitron are among others.: • • •
•
electronic timers, controlling program flow, drum movement, temperature, water level, door interlocks, designed for front and top loading versions, electromechanical timers, construction of which allows for assembly in a washing machine as well as in a dryer or a dishwasher, rotary switches.
Domestic Appliances and Automotive IndustryBitron Poland Księga1.indb 57
Manufacturing-Journal | 55 | 2010-04-28 14:55:19
ment. – In our opinion it is the best way to show the employees our appreciation and acknowledgment. We have observed also that it is a very effective motivation method – explains Mr. Damilano. So far, the human resources strategy has turned out to be an adequate one. The turnover ratio of the whole organization is at a very low level. Next to extensive development programs, another reason behind that is most probably fair compensation.
Current and future markets
The President of Bitron Poland says that none of the product category is of particular importance to the enterprise. – We do not focus and we do not plan to focus on any of the product groups or a particular component. Our goal is to respond to the needs of the customers. If they show interest in one of our manufactures, we will deliver it to them – says Mr. Damilano. The readiness to react to customers’ needs is in fact so large that the company wants to be associated with this feature.
Development of people is development of Bitron
At the current moment, Bitron employs around one thousand people globally. Nearly 80 per cent of this figure constitute the employees of the Polish plant. The division in Sosnowiec is namely an employer to 770 people. At Bitron, the development of the company is perceived as a key to success in the future. Owing to that, all employees are encouraged to build up their professional skills. – We are more than sure that growth
| 56 | Manufacturing-Journal Księga1.indb 58
of our people will result in the growth of the whole enterprise. We pay much attention to the competences of the employee. It is their skills that decide how dynamically we will develop – contends the President. In fact the company is keen on helping the employees to recognize their strengths and develop them in a way which would be beneficial to both parties. Each of the employees is offered an individually designed development scheme. Its modules depend on the employee’s current position at the company, expectations for the future as well as ingrained qualifications and already possessed competences. However, the basis of the programs are: specialist trainings, benchmarking visits, conferences and exchange projects. Bitron believes as well that its human capital is its main source of innovation. Due to that, all suggestions coming from the employees are welcomed – it is them who can most easily recognize the bottlenecks of every day work and present plausible solutions. A fundamental rule at Bitron globally is internal recruit-
At the current moment the geographical expansion plans of Bitron circulate around entering the Russian market. – It is not a plan for the nearest future though. We are aware of the market possibilities that emerge there, but what deters us is the omnipresent red tape, which lengthens all administrative and legal procedures – says Mr. Damilano. Next to that, the company does not exclude that one day it will turn its steps to the flourishing markets of China and India. Nevertheless, further growth possibilities lie in Poland. What poses a great opportunity for Bitron is one of the most recent market acquisitions. The Korean giant Samsung took over a Polish company Amica. The product offer of the latter includes among others dishwashers. Bitron hopes for cooperation, the more so that the plans of doubling Amica’s production capacity may result in a large number of orders. What may somehow influence the plans of Bitron for the nearest future is the economic crisis of 2008-2009. One of its main victims has been the automotive industry, which sales and production figures have significantly shrunk. It has found its reflection in the financial results of Bitron. Mr. Damilano claims though that the worst may still be to come. – Despite the crisis, orders form automotive companies have been arriving due to a number of institutional ventures undertaken by some governments. Once this support finishes, the suppliers may go through some harsh time. We predict that it will be no sooner that 2012 that we will come back to financial results noted in 2008 – he says. However, what will help Bitron overcome the difficulties is great experience that the enterprise gained at the beginning of its business operations in Italy. According to the President, the market of Poland is similar to the Italian one of the time – on a dynamic road to growth. Written by Aleksandra Strojek
Domestic Appliances and Automotive IndustryBitron Poland 2010-04-28 14:55:20
AR
TI CL E
S
PASSION OF CREATION
FACT BOX FULL NAME: PAS Polska Sp. z o.o. CHAIRMAN OF THE BOARD: Stefan Kaiser BOARD MEMBER: Bernd Klein ESTABLISHED: 1998 EMPLOYEES: 1050
www.pas-net.com
P
AS Polska Sp. z o.o. is part of the PAS Group – a leading developer and manufacturer of cable and panel systems for household appliances. The company is a modern technology provider which stands out as a reliable business partner, who effectively cooperates with its customers. With the extensive know-how, competence, innovative products of high quality and focus on tailored solutions, PAS is ready to meet every challenge of the market. Written by Anna Chudzik
PAS in Poland and worldwide
The PAS Group companies are active worldwide, providing technologically advanced system solutions for household appliance manufacturers. PAS, with its corporate headquarters in Neuruppin, Germany, has at its disposal 7 production plants in 5 countries – Germany, Poland, Turkey, the US and Mexico. The history of PAS goes back to 1992, when a mid-sized private company was formed out of a former state enterprise. At the beginning its profile revolved only around cable manufacturing, but thanks to the firm’s customer-oriented approach and high quality of products, its activities expanded to include plastic injection moulding and engineering. By the year 1999 the company’s workforce already amounted to 200 staff members. The first Polish plant was opened in 1998 in Opalenica, which currently specializes in the production of wire harnesses us-
ing IDC and Crimp technology as well as complete system panels for household appliances. The other Polish location of PAS is Łódź, which consists of two plants. In the first one, the company manufactures approximately one million system panels annually for the home appliance industry and supplies customers located in the area, which is based on a modern ‘shop-in-shop’ concept. In the other plant of Łódź PAS possesses plastic injection molding equipment, where the company employs screen processes, padprinting, thermo processes, IMD (inmold decoration) and IML (in-mold labeling) technologies to precisely decorate system panels. In 2008 the PAS Group became a market leader for panel systems, producing 2.5 million systems and 5 million wire harness system per year. Currently the PAS Group provides employment for some 1900 people, out of which more than a half consists of the employees working in Poland.
How to be better?
The company endeavors to act in accordance with one of its mottos, which states: “When you stop improving you stop being good.” According to Wojciech Jankiewicz, Financial Director at PAS Polska, strategic potential of the company mainly consists in the ability to adjust to the changing macroeconomic conditions and the capability to constantly optimize processes in the company. In Jankiewcz’s opinion, the key to
Domestic Appliances IndustryPAS Polska Księga1.indb 59
success is to establish internal communication between individual employees as well as individual departments of the company. Undoubtedly, PAS is the company with the potential to improve. According to Dariusz Szymański, Quality Director at PAS Polska, the strategic potential of the company can be divided into material elements, comprising technologies, machines and the firm’s infrastructure and non-material ones, such as the employees’ level of educa-
Manufacturing-Journal | 57 | 2010-04-28 14:55:21
tion, the managements of the company, the number of ideas, inventions, patents, etc. Piotr Krygowski, Production Director in Opalenica at PAS Polska, broadens the list to include the extensive know-how in the field of production of wire harness systems and panels for washing machines by the greatest household appliance manufacturers in Europe. In Mr Krygowski’s opinion, it is wire harness systems that are the most essential products in the wide offer range, which is connected with the development of the company’s machines. There are numerous goals PAS would like to achieve, but one of the main aspirations is to be ahead of the field all the time, which poses a challenge. Europe, with its dynamic market of home appliances, plays a central role for the PAS Group. On the other hand, Europe is demanding in terms of innovativeness, quickness and reliability. Today new generations of appliances are created faster than before, while new versions of appliances are introduced to the market at shorter intervals of time. In order to keep the dominance on the market, PAS carefully monitors all the market trends. One of the latest tendencies is to introduce environmentally-friendly technologies. Moreover, a changing global market requires developing a new type of partnership between customers and suppliers. PAS is willing and ready to meet all those challenges.
Building customer confidence
The success of each and every company depends on various factors, but what seems indispensable here is gaining the customers trust. Joachim Schrader, the Director of Sales and Marketing at PAS Group and Ulrich Worbs, the member of the Sales and Marketing Department at PAS Group encapsulate the idea of gaining customer confidence in the following way: “We know from experience that reliability, proper price to quality ratio, open communication and the attitude towards solving problems, combined with a wide scope of competence, have an important influence on building the trust.” Mr Schrader and Mr Worbs admit that the PAS Group lays particular emphasis on the partnership with its customers. As a systems partner and also the supplier of components, PAS can offer a wide range of services, starting with the designing and construction, ending with the serial delivery, which works in accordance with one of the company’s
| 58 | Manufacturing-Journal Księga1.indb 60
Domestic Appliances IndustryPAS Polska 2010-04-28 14:55:27
mottos: “Your ideas – our solutions.” What is more, the success of PAS is intertwined with the success of the customers, which is why the company actively supports them in many fields. PAS has always focused on fulfilling the wishes of its clients to keep them satisfied. As already pointed out, the popularity of the PAS products is determined by their high quality and reliability. Apart from the complex service package, the PAS Group offers its clients the professional consultancy, innovativeness and on-time delivery. All of that made it possible to build and solidify the customer confidence, which is the cornerstone of the business.
Human potential
The success would not have been possible without the highly-qualified employees, who actively contribute to the development of the company and constitute one of its strongest pillars. In 2009 the average number of staff members in Pas Poland amounted to 800 permanent employees and 250 temporary ones. PAS makes an effort to be perceived as a reliable and stable employer: “Reliability manifests itself in complying with the rules and regulations stated in the Polish labour legislation, clarity of the internal personnel procedures (e.g. recruitment procedures) and the concern for the employees’ development (e.g. subsidizing
Domestic Appliances IndustryPAS Polska Księga1.indb 61
their education). As for the stability of jobs, we try to ensure it using the available tools such as temporary job or flexible working hours,” says Jarosław Szaga, Director of Human Resources at PAS Polska. Elaborating on the personnel policy, Mr Szaga enumerates some of the company’s actions, aimed at motivating as well as supporting the employees. Apart from ensuring safe working conditions or organizing and paying for the group transport of the employees to work, PAS fosters showing one’s initiative and creativity through the implementation of employee suggestion program. The financial help takes the form of giving the presents for the employees’ children, Christmas vouchers, loans, etc. The good atmosphere at work is strengthened during the social events, such as trips and family picnics, but also the regular staff meetings with the Board. PAS does not forget about the development of young people, thus, together with other companies, organizing apprenticeship for mechatronic engineers or internships for the school students so as to help them choose their future career path. Moreover, as part of the non-business activity, PAS sponsors local cultural events and cooperates with a chosen school and children’s home. Since people are of paramount importance to creating the success story of PAS, one of the company’s goals is to create new jobs, as pointed out by Mr Krygowski.
Resisting the crisis
Owing to the crisis, the sales of home appliances dropped all over the world. However, according to Jakub Bok, Sales Manager at PAS Polska, Poland is the sole country in Europe which did not feel the crisis in the home appliances sector. Within the last year, the sales grew by 2% in Poland, which is a good result, when compared to other European markets, which suffered a drop by 25%. As Mr Bok continues, Poles tend to buy more and more, and the Polish market has a great potential to develop. Although the dynamics of growth has lessened because of the crisis, PAS was able to make the most of its opportunity and strengthen the market position: “This year we have bought a new production hall, which enabled us to perfect processes occurring in the company. The clients appreciate the constant development of the enterprise and they unanimously agree that PAS is a stable and innovative company.”
Manufacturing-Journal | 59 | 2010-04-28 14:55:29
S TI CL E AR
STEERING TOWARDS MODERNITY
FACT BOX FULL NAME: Biazet S.A. PRESIDENT: Adam Morawski OPERATIONS: design and production of electrical equipment ESTABLISHED: 1970 EMPLOYEES: 1215 (December 2009) REVENUE: 623 mln PLN (2009)
www.biazet.pl
H
aving created cutting-edge technological complex, Biazet S.A. became one of the largest Polish producers of small domestic appliances, such as vacuum cleaners and coffee makers, marketed under by Philips under their brand name. Apart from specializing in engineering and manufacturing, Biazet’s corporate activity also revolves around leasing of commercial, office, production and storage facilities. Biazet has proved to be a reliable business partner as well as highly efficient company which is focused on improvement and long-term growth. Written by Anna Chudzik
Transformed into a giant
The beginnings of the company date back to 1970 when it was established as a manufacturer of wire-wound TV components in Białystok. Among the breakthrough moments in the company’s development one can enumerate the introduction of the first ignition coil in 1985 and the first TV set in 1988. The period between 1990 and 1997 was fraught with difficulties because the political transformation put numerous enterprises at a disadvantage. The situation decreased Biazet’s competitiveness in the market, made it reduce the number
of employees and also sell off a substantial portion of its assets. In 1994 Biazet finally transformed from a state-owned enterprise into a private joint-stock company with majority of private shareholders, but the date that particularly came down in the history of the company was 1997, when it started its cooperation with Philips, which has yielded best results to date. Thanks to experience, know-how, willingness to improve and usage of the latest organizational and business methods, Biazet became a successful modern enterprise and one of the biggest employers in the region.
Popular products for
international corporations
Biazet specializes in engineering and producing electrical equipment, mainly small household appliances and electrical components for Philips Consumer Lifestyles, Philips Consumer Luminaires and Eaton Electric. Thanks to over tenyear cooperation with Philips, which is an international concern, Biazet learnt how to improve, raise quality standards and optimize the costs. What actually makes the company’s products popular among its customers is the ability to combine high quality as well as worldclass level of service, typical for the “old” EU and relatively low costs of production, typical for the “new” EU or the “Low Costs” countries, which are characterized by the production flexibility (quick
| 60 | Manufacturing-Journal Księga1.indb 62
Domestic appliances IndustryBiazet 2010-04-28 14:55:32
adjustments to changes and very short planning horizon). Biazet is renowned as a reliable partner and a flexible enterprise anticipating customers’ needs. Currently, the products assembled by Biazet for Philips are for example vacuum cleaners (Specialist, Universe and Mobilo), drip-filter coffee makers (Essence, Gaia, Basic), and Senseo II coffee maker. As Adam Morawski, President and CEO at Biazet S.A. claims, one of the company’s main priorities nowadays is staying with the always developing Senseo and Living Color (a lamp series) product lines, as these two Philips flagship products identify Biazet as a key supplier. The other priority is to develop the customer portfolio and free from overdependence on one customer, thereby expanding the range of customers while developing the Philips business. Since all Biazet’s products are earmarked for international corporations, the company strives to win new customers also among ones.
Courageous decisions as a source of success
Until recently Biazet has still been burdened with the complexes of the 90’s. Management focus was on cutting costs and avoiding commitments and even minimal risk at all cost. Apart from that, Biazet was a subcontractor to Philips for many years, supplying the workforce, the operators or the customer’s production lines and process. Today it is recognized as an OEM and Contract Manufacturer, depending on the specific product line. The source of Biazet’s success can be discerned primarily in courageous decisions and willingness to develop, which is explained by Mr Morawski in the following way: “In 2007, when I had joined the company, we took a hard look at our 2005/06 strategy and decided that bold actions had to be made in order to meet the objectives we had set forth for the years 2007-2010. The most key decision was to start investing into new competences before a return was ensured, rather than focus on cutting costs down to the bare bone and avoiding all risks at all cost. We have also significantly changed our corporate culture (…), thus started believing that by working together as a dedicated team we can make it happen, even if calculated risks must be taken. From a hierarchically organized company, authoritatively micro-managed by its former top executive, we became a project-based organization, fostering teamwork and seeing
our leaders’ role more as coaches than rulers. This has helped to free up vast amounts of motivation and responsibility among rank and file, consequently enabling our successes.” Within just two years, Biazet has developed a number of key competences, especially in the engineering, manufacturing, logistics, and project management areas. Today, Biazet can offer world-class service, extreme flexibility, very short lead times, and creative, sound customer-focused solutions at very competitive prices. It has grown from a subcontractor, to an OEM company, more than doubling its blue collar workforce and increasing sales more than sevenfold. Biazet, assisted by one of the world’s top Lean consultant, is currently going through a comprehensive Lean Manufacturing deployment, in order to further optimize our flexibility, quality and costs.
Team spirit and
can-do culture
The success of the company would not have been possible without the wellcoordinated group of people working for the common
Domestic appliances IndustryBiazet Księga1.indb 63
goal. As admitted by Mr Morawski, the staff, which fills him with pride, constitutes Biazet’s strategic potential. Over the last two years of the rapid growth journey, Biazet has seasoned competent and creative staff as well as can-do corporate culture. The vision of the company focuses mainly on the point: “From concept to market – we make it happen.” Currently Biazet employs approximately 1100 production workers and 115 white-collar and administrative ones (December 2009). What favors the good atmosphere at work are modernized production lines as well as flexible working hours. As for the first factor, in 2009 Biazet launched the first line which complies with Lean Manufacturing system, thus occupying less space and being effective and comfortable to operate for employees. The company is will-
Manufacturing-Journal | 61 | 2010-04-28 14:55:35
its own plastic injection molding equipment, which would reduce the costs of production and make the company independent of some subcontractors. The next major step is the expansion of the commercial service centre. Biazet is already an owner of the commercial, service and office facilities, which are to be revitalized and widened to include a new multidimensional complex.
More things to be proud of
President & CEO „Biazet” S.A. - Mr. Adam Morawski with employees
ing to improve the line and also modernize the remaining ones. When it comes to the other factor, the President explains that “flex time is but one method for growing employee loyalty, as it permits a more stable crew, paid at a flat level throughout the year, while our orders during the same time vary dramatically.” People-focus is a critically important element in the company’s strategy – “We focus on developing good relationships with our employees, on growing their competence, helping them mature and grow into ever more challenging and demanding positions,” adds Mr Morawski and continuous, “I also want us to be recognized as a responsible, people-oriented employer, with whom one can have a stable future as well as intense development and growth. Over the past two years, we have been on a pretty wild ride and I would like the labor market to recognize that with Biazet one can grow better and work in a more exciting environment than with any other company in our region.”
competences, recognized by Biazet as critical growth factors in the industry. It is also willing to offer its customers ever more mature and comprehensive solutions and even wider service. In some ways the company is going against the fashionable trend of outsourcing by acquiring what others want to outsource, as well as integrating functions that have been purchased from third parties before. Apart from widening the offer range, Biazet plans the investment into
The company’s mission is to provide word-class engineering, production, and property management services. Always focusing on a stable and high level of quality, the company received the ISO 9001:2000 certificate in 2001 and is at the time of implementing ISO 14001 norm, which is to prove that the company’s activities minimize the risk of negative impact on the environment. Biazet means quality, which is proven by the popularity it enjoys among its customers. However, the company has been rewarded with numerous awards and distinctions, which additionally asserts its rank. Among the most recent distinctions there is the Business Gazelle award (the 10th place in Poland and the 1st in
Oriented towards investments
The company strives to invest into future, which means developing specific the Podlasie province), which Biazet has been receiving every single year since 2005. Over the last few years, it has also been recognized several times with the Philips Supplier Award. This year it has been awarded by the Forbes magazine with Diamonds (Diamenty) distinction.
| 62 | Manufacturing-Journal Księga1.indb 64
Domestic appliances IndustryBiazet 2010-04-28 14:55:38
AR
TI CL E
S
RUNNING LIKE CLOCKWORK
FACT BOX FULL NAME: AUTOMATYKA Sp. z o.o. PRESIDENT: Artur Maciejczyk OPERATIONS: Industrial Automation ESTABLISHED: 1997 EMPLOYEES: 200 REVENUE: 25 mln PLN
www.automatyka.tarnow.pl
F
or more than a decade of its activity Automatyka Sp. z o.o. (LLC) from Tarnów, Poland, has grown rapidly and become one of the leading providers of digital control and measurement automation systems. Its comprehensive solutions have been duly appreciated by petrochemical and power industry. Written by Bartosz Sowński
Traditional and Innovative
Nowadays Automatyka Sp. z o.o. enjoys recognition as a leader in the branch of designing, execution, implementation and service of industrial measurement and control systems. Although the company was founded in 1997, its true beginnings date back to the 1920s’. In the course of privatization it inherited the tradition of Zakłady Azotowe S.A. established in 1927, and being more precise, their Department of Measurements providing automotive control systems for the industry. The management of the business soon set themselves an ambitious objective and between 2000 and 2007 broadened the scope of activity, launching brand new services and solutions which include thermovision, CCTV, supervision, optic fibres technology and calibration. The last of these could not be delivered if was not for a laboratory awarded the accreditation certificate in 2007. The market demand for technologically ad-
vanced solutions made the company open its branch in Katowice in July 2009.
Rock Foundations
For a decade of its independent operations Automatyka Sp. z o.o. has managed to create a technological park containing machine workshops and modern diagnostic, repairing and calibration studios for measuring devices and elements of control systems. However, infrastructure does not make the only paragon of its power. People are equally important there. More than 200 highly qualified workers look after the manufacturing process at the present time. Relevant experience as well as expertise in theoretical aspects of chemistry, energetics and ecology enable them to maintain a desired quality of the products further substantiated by PN-EN ISO 9001:2001 certificate. Automatyka as its holder means that all the teams there comply with severe quality requirements, be it design, implementation, installation, service, monitoring or internet teams.
Offer in Brief
The wide array of services delivered by Automatyka Sp. z o.o looks truly impressive. Firstly, the catalogue includes comprehensive service, assembly and starting of industrial measuring and control systems employing PLC program controllers and DCS systems. Secondly, on offer there are also visualization, installation of nets and computer
Industrial AutomationAutomatyka Sp. z o.o. Księga1.indb 65
Manufacturing-Journal | 63 | 2010-04-28 14:55:40
software as well as repairs, calibration and check of instruments. Thirdly, the company provides thermovision measurements, technical services for people and property protection, technical advising, expertise, designs, training and spare parts manufacturing. This extraordinary assortment of solutions has been made possible thanks to the technological powerbase. The company takes particular pride in the calibration laboratory holding the certificate of Polskie Centrum Akredytacji (The Polish Centre for Accreditation), which confirms that the laboratory meets requirements of PN-EN ISO/IEC 17025:2005 quality norm with regard to industrial sensors of resistance thermometers and thermoelements of the type S, J, K, N, N, T, E.
Moving Parts of a Machine
In order to present the offer in detail it is necessary to spare a few words on each section of the business. The first of these, design team, is responsible for a full range of design and execution works. It also issues opinion concerning offers, provides specialist training and technical consultancy as well as works on completion and specification of deliveries. It holds a license of MSWiA (Ministry of the Interior and Administration) indispensable for designing, assembly of digital supervisory (CCTV), fire (SAP) and anti-burglary (SSWN) television system service. The next one, digital control systems team, specializes in designing, configuration, implementation and current service of DCS and SCADA computer control systems fitted with PLC programs. This party takes extreme care to optimize manufacturing processes and creates computer networks which utilize optic fibres technology. Analytics and weighers team can be in turn relied on when it comes to stationary detection systems of explosive and toxic gases and mobile exhaust-gases analysers. These people calibrate and design hygrometers, toxicity meters and explosion meters as well as do inspection, maintenance and rating of industrial and analytic weighers. Maintenance and assembly team of measuring installations not only puts these systems together but also carries out prefabrication of cabinets, control desks and panels, cable trays and mobile components as well as performs orifices and measuring sections. Maintenance and servicing team of executive modules and equipment is ready to perform twenty-four-hour op-
| 64 | Manufacturing-Journal Księga1.indb 66
eration service of these modules. Moreover, it prepares verification, rating and performs checks of appliances passed on for exploitation including regulating and ball valves, throttles, pneumatic, electric, piston and rotational actuators. These guys also manufacture spare parts and spend much of their time conducting professional training and consultancy. Renovation and service team of measuring and control equipment is on the alert 24/7 so as to secure operation service of measuring appliances and control systems. This section also performs assembly and renovation of control installations including tailormade office equipment and air-con.
Top-notch Solutions
Optic fibres technicians complete projects consisting of design, service, delivery, assembly and repair of optic fibre communication systems. Hence, in order to ensure custom-made solutions they first visit customers’ premises, then select top-notch appliances and execute passage connections, branches and endings of optic fibre lines in various standards. While taking measurements and carrying out diagnostics they utilise state-of-the-art appliances such as reflectometer and optical power meter. Specialists from thermovision department secure services necessary in the process of applying for energetic test. By means of the up-to-the-minute thermovisual camera they detect preemergency states in the heating circuit, which allows the customer to cut further heat losses, plan necessary renovation as well as save time and money. Last but not least, the company creates audiovisual monitoring systems (CCTV) of sports, church, industrial and public utility facilities. Its supervisory television systems are also dedicated to production control as well as shop, mass events and dangerous spots supervision. If utilised for property protection, these systems work as a support for anti-burglary signalling systems.
Market Recognition
Taking only a brief glance at the solutions Automatyka has on offer, one should come to a conclusion that such a wide assortment of goods and services must have been appreciated by the market. The facts will only prove it further. For the last four years the company has been always awarded the title of “Gazela Biznesu” (“Business Gazelle”). It
Industrial AutomationAutomatyka Sp. z o.o. 2010-04-28 14:55:41
has been also honoured by the jurors of the “Przejrzysta Firma” contest (“Transparent Business”). It will come as no surprise if we enumerate quality certificates held by the enterprise. These are as follows: license of technical security of the second stage and the designer powers of the Polish Chamber of Alarm Systems to design the technical security systems in the classes SA1-SA4 (necessary for audio visual monitoring execution); Powers of Radiological Protection Inspector of the type: IOR-0, IOR-1; PN-EN ISO 9001:2001 quality certificate referred to earlier in the text. Striving to be on top of today’s technology, the company has established liaison and achieved the status of the Authorized Partner of the following companies: Emerson Process Management, Endress+Hauser, Astor. No wonder, therefore, that the business has had an opportunity to cooperate with the giants of petrochemical, refining, power, gas and automation industry including Grupa Lotos and Orlen refineries; power plants in Ostrołęka, Lubln, Rzeszów and Tarnów; HKW Hafen Munster, Germany;Vattenfall Heat Poland; Rafako; Linde Gaz Polska; Karpacka Spółka Gazownictwa; Rockwell Automation Services; and Andritz, France.
Ecology and Sport
The board of the company is particularly keen to reach possible levels of sustainability. Hence a series of initiatives which make it possible to meet the demands of stern ISO 14001 norms and directives concerning waste, exhaust gases and dusts; hence recycling and the audit issued by the Environmental Conservation Inspector of Lesser Poland. As far as healthy lifestyle and sports are concerned the business provides financial backing for mountain bikers (SOKÓŁ group), two employees taking part in gruelling marathon competitions and a football team wearing the company’s logo, too. These guys often play against the squads representing Automatyka’s business partners and thus make it possible to tighten the bonds with them on the grounds other than merely professional. That leads us to the conclusion. Football is about rivalry and cooperation. Just like entrepreneurship.
Industrial AutomationAutomatyka Sp. z o.o. Księga1.indb 67
Manufacturing-Journal | 65 | 2010-04-28 14:55:44
S TI CL E AR
WORLD-CLASS PLASTIC COMPONENTS
FACT BOX FULL NAME: Groupe Plastivaloire Eastern Europe PRESIDENT: Andrzej Bilip OPERATIONS: Plastic Injection ESTABLISHED: 1996 EMPLOYEES: 1000 REVENUE: 100 M €
www.plastivaloire.com
T
he French industrial group PVL (Plastivaloire) owns twenty plastic processing plants in the world, three of which are located in Poland. Using the injection moulding method, the company is a Polish leader in the production of plastic components for a variety of industries, especially the TV, Automotive, Domestic Appliances and Electric sectors. As a high-tech enterprise as well as reliable business partner, PVL can boast a cooperation with world-class concerns, such as PHILIPS, LG, SONY, VALEO. Written by Anna Chudzik
Three sisters
There are three sister factories in Poland which operate within PVL Group. Their history dates back to 1996, when Plastivaloire Group decided to build a factory in Kwidzyń and launched the production of the components for TV sets. Thanks to the rapid development Plastivaloire established a new factory, which took place in 1998 in Kętrzyn. The production there was focusing on the domestic appliances and lighting branches. The last factory was opened in 1999 in Gliwice, which was directed towards the automotive and televisions sectors.
Since that moment the Group has been investing in infrastructure, technology and human resources, which resulted in the expansion of each factory two times. Today the Kwidzyń FPK, Kętrzyn FPK and Gliwice FPG plants can boast an impressive machine stock, which makes it possible to produce virtually all kinds of injection moulds. FPK in Kwidzyń specializes in the production of components for TV sets and also in the decoration of medium and large components. As for FPK in Kętrzyn, it focuses on the parts used for coffee makers, vacuum cleaners as well as fluorescent and regular lamps, while FPG manufactures car parts (including the front module for FIAT PANDA), TV-set casings and components used in the electric industry.
Not only a supplier
PVL takes pride in its cooperation with prestigious international corporations, which use the company’s products in the manufacture of TV sets, electric and lighting equipment, cars, or computer accessories. Among its customers there are world leaders in the respective fields, such as LG, PHILIPS, SONY, JABIL, TPV, VALEO, GRUPA MAGNA, FAURECIA, BOCH, DAIKIN. Such names are the best confirmation of the popularity of products provided by PVL Group. As the company admits, building customer confidence is a long-term process which consists of various factors. High quality
| 66 | Manufacturing-Journal Księga1.indb 68
Plastic componentsPVL Group 2010-04-28 14:55:45
Production and services
biuro@profes.org.pl | www.profes.org.pl
We offer: Own construction desk Toolmaking services Production of injection moulds: punches, dies, metal moulds, moulders plastics on injection moulding machines - up to 500 g Machining using CNC machines Thermo - chemical treatment Electrolytic machining using die sinking and wire cutting machines Services on presses - up to 63 tones Welding steel and non - ferrous metals
Assembly, repair and welding services Transport services ,FTL cargo Construction of paint spraying lines
Przedsiębiorstwo Usługowo - Produkcyjne „Cesmex” Ryszard Czeszejko-Sochacki Gniewskie Pole 4a, 82-500 Kwidzyn | tel./fax +48 55 275 74 38 | mob. +48 601 663 620 firma@cesmex.com.pl | www.cesmex.com.pl
Z.P.U. Profes S.C. J. Gnitecka - Lech, Z.Lech | ul. Łąkowa 29 f 82-500 Kwidzyn | tel./fax: 0048 55 279 51 86
WE OFFER MORE FOR ALL WWW.BUSINESSPL.COM
www.manufacturing-journal.net
Manufacturing Journal
Here is the place your
for
advertisement Please contact us for more information and examples of our offer. e-mail to: info@manufacturing-journal.net Plastic componentsPVL Group Księga1.indb 69
Manufacturing-Journal | 67 | 2010-04-28 14:55:49
of products, reliability of delivery and technical support are a point of departure for creating an effective supplierclient relationships. The willingness to listen to client’s suggestions proves that customer satisfaction is the utmost goal of the Group. All customers must be treated individually, because each sector they represent is specific and thus governed by its own rules. PVL would like to come up to all clients’ expectations, which necessitates the ability to adjust to their individual needs. Moreover, the Group strives to be perceived not only as an innovative supplier, but also a reliable business partner, which is one of the key points in the company’s mission. That is why, it takes an active part in projects, which are developed and carried out together with customers. To anticipate their needs, the company offers complex solutions, instead of limiting its activity to plastic injection moulding. Moreover, the professional preparation of projects, coupled with their quick implementation, helps the company to maintain the mutually beneficial partnership. The source of the company’s success can be discerned precisely in the devotion and concern for building the positive relations, as it makes customers stay with PVL.
Quality and technology
What sets PVL apart in the market is the high quality of products and cutting-edge technology the company implements in the production process. Quality and durability of are overriding features of the PVL products. They un-
| 68 | Manufacturing-Journal Księga1.indb 70
doubtedly contribute to gaining customer trust and developing a fruitful cooperation with the partners. Plastivaloire is a modern company, which makes use of the latest technological and engineering solutions introduced by world leaders in the field of plastic processing. The Group possesses an extensive stock of machines, thanks to which the company guarantees comprehensive customer service, ranging from injection to the process of assembly and varnishing. The company can boast considerable technical know-how for the production in a variety of technologies, including precise injection moulding or high gloss injection moulding technique, which makes use of steam. Additionally, the company has at its disposal extrusion production lines. As admitted by the corporation, it is proud of its high-gloss TV set and monitor casings, specialized products for the automotive industry and also complex products earmarked for electric and domestic appliances branches, which require complicated process of decoration and assembly.
Potential to fulfil
PVL does not forget about investing into future. One of the strategic goals of the company is to purchase new machines and implement modern technologies, such as the MRP production planning systems, which are used to manage manufacturing processes. Moreover, PVL is striving to create a flat management system, which involves local management of the company, thus increasing its competitiveness. PVL demonstrates
Plastic componentsPVL Group 2010-04-28 14:55:57
its ability to make the most of incoming market opportunities. Within last five years a number of TV sets manufacturers has decided to invest in Poland, Slovakia and Hungary, which created a great potential for development of plastic processing companies like PVL Group. Another sector where delocalization is taking place nowadays is the automotive industry. The R&D department in France is currently working on new technologies to be implemented in Eastern Europe. Another advantage of the Polish companies of PVL Group is their favorable location, which makes it possible to supply clients both from Western Europe and Russia. Owing to the company’s cooperation with forwarding companies, which allows advanced logistics, it can produce goods to all clients regardless of their location. Strategic potential lies also in highly-qualified people working for the company. The employees in sales and customer service departments speak various languages, even the Asian ones. The total number of the staff in Poland amounts to over 1000 people and it is rising. PVL invests in the personnel by organizing numerous trainings so that they would stay with their employer. Ad additional motivation is the amount of earnings, which also translates into a good atmosphere at work.
that PVL is willing to take even challenging and capital-intensive projects. The company complies with the ISO 14000 norm, which introduces environment protection procedures. Furthermore, all Polish factories possess ISO 9001:2000 certificates, while FPG was the first of them to implement a quality management system in accordance with Technical Specifications for the automotive industry, which is certified by ISO TS 16949. Among the distinctions it has received, there is the Business Gazelle title, which was given to the company for several times. Moreover, the company was repeatedly rewarded with the Best Supplier and the Qualified Supplier awards.
Achievements
PVL Group is recognized as a reliable supplier with an extensive experience in the market. What also helps to attract client’s attention is the good financial condition of the company, because it means
Plastic componentsPVL Group Księga1.indb 71
Manufacturing-Journal | 69 | 2010-04-28 14:56:00
S TI CL E AR
A ROOF OVER YOUR HEAD
FACT BOX FULL NAME: F.P.U.H. Blach-Stal Paweł Skawski PRESIDENT: Paweł Skawski OPERATIONS: Construction ESTABLISHED: 1994 EMPLOYEES: 120
www.blachstal.pl
A
company with an extensive range of roofing sheet products, Blach-Stal specializes in manufacturing tile sheets and trapezoidal sheets and it provides customers with high-quality solutions both in Poland and abroad. State-of-the art technology, professional approach and attention to detail are to ensure clients’ satisfaction and make people feel at home. Written by Anna Chudzik
From trading to manufacturing
The beginnings of Blach-Stal date back to 1994, when the company only traded in sheet metal roofing products. However, it soon decided to start its own production, which resulted in the opening of a production plant in the city of Bochnia in 1999. At the initial stages, the scope of production was narrowed down only to three profiling lines. Now the company can boast cutting-edge machine facilities, which enable it to manufacture trapezoidal sheets, tile sheets as well as sheet elements and roofing accessories. For over 10 years the company has opened 40 braches all over Poland and in Slovakia. It exports products to the Czech Republic, Ukraine, Hungary and Slovakia. A steady growth in demand has also been noticed on German and Austrian markets, which are already filled with other kinds of roofing products. Moreover, Blach-
| 70 | Manufacturing-Journal Księga1.indb 72
Stal supplies its products to numerous wholesalers in Poland and abroad.
How to satisfy the customer?
The offer of Blach-Stal is addressed primarily to individual clients, as single family housing is developing dynamically. However, the company’s products are also used for industrial buildings, such as warehousing facilities. As the company admits, it has always made every effort to satisfy customers and win their confidence. In order to achieve this aim, one has to take care of all aspects involved in the customer service. First of all, the company strives to demonstrate a clientoriented approach, which entails a high level of flexibility. It means that it is necessary to follow new trends and adapt to customers’ needs, which are changing all the time. Moreover, in order to live up to all expectations, the company is willing to take responsibility for its products and service which covers all actions ranging from taking measurements to supplying the product to the receiver. The firm is distinguished by the ability to complete orders quickly and efficiently, which is possible also thanks to is own fleet of vehicles adjusted to transportation of roofing sheets. Customer trust has also been won thanks to the people working for Blach-Stal, as they create its image by providing professional, friendly customer service and building positive relations with clients. All those ele-
ments constitute the origin of success, which is customer satisfaction. However, Blach-Stal is aware that the success would not be possible without the wide array of top-quality products on offer.
KING, DAKOTA, ELITA
…and more!
From the very beginning of its activity, Blach-Stal has attached particular importance to the quality of the raw material used for the production of roof elements. That is why it cooperates with the best world manufacturers, such as ThyssenKrupp, ArcelorMittal or U.S. Steel which are renowned for the firstrate steel products. Moreover, the company endeavours to protect its roofing sheets in the best possible way by zinc and polyester coating, which makes them highly durable and resistant to extreme weather conditions. To additionally protect metal sheets, Blach-Stal can coat each metal sheet with protective foil upon the client’s request. Apart from high quality, products of Blach-Stal enjoy great popularity among Polish customers because of a wide range of interesting colours which give the roof more individual character. The product which plays a prominent part in Blach-Stal is tile sheet, perfect for both new and renovated roofs. It is immensely popular for being light and easy to install, while it also has an undeniably attractive appearance. At the moment the company
Construction IndustryBlach-Stal 2010-04-28 14:56:02
Find out that “business is business” and be part of it!
businesspl.com
Via our magazine BusinessPL you can: •
contact influential people in business;
•
be found easily and available;
•
take part in important events;
•
read experts’ advice;
•
raise your point, tell about your company;
•
adopt the right strategy and direction;
•
build your image;
•
get to know the language of business;
•
talk in a “business” manner;
•
access business information from the inside;
•
get to know the well-planned, strategic and effective BUSINESS;
Księga1.indb 73
2010-04-28 14:56:04
can offer three types of tile sheets: KING, DAKOTA and ELITA. As for the KING tile sheet, its subtle forming profile makes the roofed building appear light and graceful. The ELITA sheet is characterized with a classic high profile, which draws upon the shape of interlocking tiles. When it comes to the DAKOTA type, it is highly inventive in appearance, made of top-quality materials and additionally protected with multi-layer coatings. It is also noteworthy that all of them are available in numerous colour variations. Besides manufacturing tile sheets, Blach-Stal specializes in trapezoidal sheets which come in various profile heights and can be used for roofs with various roof spans. The Blach-Stal profiles are fit not only for roofing purposes; low profiles can also be used as soffit board, while the high profiles as formwork. Apart from roofing sheets, the company can offer various sheet elements such as flumes, crowns, side metal accessories, under-gutter strips, over-gutter strips, snow guards, wind beams or ridge tiles. Furthermore, by focusing on customers, Blach-Stal offers them tailor-made sills of high quality. Thanks to long-term business partnership with companies such as ThyssenKrupp, ArcelorMittal, Corus, U.S. Steel, Fakro, Kaczmarek, Galeco, Gunnebo and Koelner, the company also provides its clients with various accessories, which are invaluable for the solid completion of a roof. These include steam-permeable foils, foamed polyurethane seals, touchup paints, screws, Fakro windows, Kaczmarek gutter system and Galeco gutter system. Having already become successful on the market, the company does not rest on its laurels, as it is willing to enrich the offer by developing new products and setting trends in roof design. Blach-Stal believes that client trust obligates the company
| 72 | Manufacturing-Journal Księga1.indb 74
to seek new solutions on a regular basis.
Conjuring up a positive image
What constitutes a strategic potential of Blach-Stal is the people working in all sales branch offices. More than 100 staff members, most of whom are sales representatives, build positive relations with customers and create the company’s image. Since the role of the staff seems to be invaluable, the company attaches much significance to the selection of the best possible employees of professional integrity, who are truly dedicated to the company. Thus, the criteria of their assessment include devotion to work, propriety, enthusiasm and cus-
Construction IndustryBlach-Stal 2010-04-28 14:56:06
tomer-oriented approach, as Blach-Stal perceives success in terms of customer satisfaction. Staff members are also the first to inform the company management about changes in customers’ preferences or the specificity of a local market. Recently, the company has observed a dynamic development of single family housing, which comes as an advantage for Blach-Stal. What has also become noticeable is a shift of emphasis in customers’ priorities. They prefer the products of higher quality and their expectations are rising all the time, which is why achieving highest quality benchmarks is so crucial. Blach-Stal strictly cooperates with its suppliers so that the customers can have an opportunity
to choose and customize the products.
Non-business activities
Apart from friendly approach, prompt and reliable service as well as capacity to respond to customers’ demands, Blach-Stal is involved in various nonbusiness activities. One of them is connected with sports; for a certain amount of time the company provided financial patronage to Bębenek Rally Sport team. It also assists in organizing various sports events for young people. Moreover, the company gives to charity; it supports both individuals and organizations. On the other hand, it recently sponsored the event organized by the Town Hall of Bochnia, commemorating the outbreak of World War II.
Solidity confirmed by accomplishments
Blach-Stal can be proud of its achievements. The greatest sense of achievement for the company comes from customer satisfaction. However, its efforts did not come unnoticed, as the company has been granted numerous awards, additionally confirming its rank. Among the flagship ones there was Gazele Biznesu title (Business Gazelle), granted for a few times, or Lider Przedsiębiorczości (Enterprise Leader), the award granted at the EXPOBUD fair in 2003. Apart from that, Blach-Stal was awarded with the title Solidny Partner (Reliable Partner) by numerous companies. All the distinctions are the best confirmation of the company’s reliability, which is why the Blach-Stal brand name as well as its products should always connote SOLIDITY. All in all, it is necessary for each and every roof to be solid.
Construction IndustryBlach-Stal Księga1.indb 75
Manufacturing-Journal | 73 | 2010-04-28 14:56:08
S TI CL E AR
THE GOOSE THAT LAYS GOLDEN EGGS
FACT BOX FULL NAME: Fermy Drobiu Woźniak Sp. z o.o. PRESIDENT: Adam Woźniak OPERATIONS: Eggs production ESTABLISHED: 1986 EMPLOYEES: 1300 REVENUE: 563.144.000,00 PLN
www.fdw.pl
E
very four egg consumed in Poland comes from Fermy Drobiu Woźniak (Woźniak Poultry Farm). If it is not good enough already, you should know also that only 30% of what the company turns out is put on the Polish market. The business is located in Żylice near Rawicz (the voivodeship of Major Poland), where more than 20 years ago Zbigniew Woźniak built it up from scratch. Its rapid growth stands out as a perfect example of the simple truth. As a beginner you do not need wads of cash to achieve success in business. It is enough to know that you should neither put all your eggs into one basket nor count your chickens before they are hatched. Written by Bartosz Sowiński
Up from Scratch
In 1986, when Mr. Zbigniew Woźniak started doing business virtually from zero in Żylice, no one gambled on it that only one henhouse would turn into a foundation for the largest egg producing farm in Poland and Europe. Whereas initially it used to turn out up to 50,000 consumer eggs a day, nowadays it is capable of producing, mind you, nearly 5.5 mln. How it all happened may provide a lesson not only for those who are about to set up their own enterprise. The Woźniaks never squandered profits they generated and always made their money work for them. They could not carry it off so successfully if it was not for the founder’s resolve. Mr. Woźniak
was well aware of the fact that nothing would secure the company’s expansion better than his personal governance. That is why his egg farm was originally structured as a family business. It proved a right decision taken in a right time. Capitalism did not take off a flying start then yet and many people still underestimated the importance of private ownership. At the present time, as the world strives to handle the financial crisis triggered off by the corporate management culture, one might again recognise the values of those entrepreneurs and workers who, having once set up the business, stuck up together through thick and thin, just as if it was a family. For that matter, it is Zbigniew’s elder son Adam who presides over Fermy Drobiu Woźniak and his younger brother and sister help him run the trade. From their head office in Żylice they manage the nexus of farms dotted around the regions of Major Poland and Lower Silesia.
Success in Numbers
Now let us pass on to some facts and figures. Fermy Drobiu Woźniak look truly impressive here. It should be emphasised again that there is non such in either Poland or the whole of Europe. Only last year did the farm produce more than 2 bln of consumer eggs. Currently, the business supplies 25% of the demand for eggs in Poland. This means, therefore, that every four egg eaten in Poland comes from the Woźniak compa-
| 74 | Manufacturing-Journal Księga1.indb 76
Food & Beverage IndustryFermy Drobiu Woźniak 2010-04-28 14:56:14
ny. Nonetheless, only 30% of the 5.5 mln eggs produced there each day is available on the Polish market as all the rest is exported. These data have to lead to the following conclusion. Fermy Drobiu Woźniak prove geared up enough to cater for all the Poles who enjoy eggs as their meal. For those in the know it will come as no surprise. The Woźniaks’ technological and infrastructural base seem little short of a farming powerhouse with its 10 mln hens, 70% of which lays one egg a day. The remaining livestock makes up either the herds of chicken or mother hens. Nearly 1300 people are working there, including 848 production workers, 302 drivers and 120 administrative officers. The list of facilities comprises not henhouses only but also siloses, feed manufacturing and mixing plants, hatcheries, breeding farms, sorting plants, warehouses and own laboratory. Last but not least, there is also a transport fleet of more than 100 cars, namely 60 refrigerated lorries for egg transport, 20 cistern-silos lorries for feed transport and 30 lorries for grain transport. A real empire indeed. Having said that, one should bear in mind that the management of Fermy Drobiu Woźniak will not rest on their laurels. It is exactly the opposite. Suffice it to say that on the agenda of their recent investments one might find the following: firstly, a newly purchased farm in Kleczew near Konin; secondly, a feed mixing plant in Lasocice near Leszno, a project partly funded by the EU; thirdly, new henhouses in Żylice. Two more plans underway should be mentioned, too, that is the renovation of the older henhouses as well as land purchase for future investments.
Eggs Always Intact
It does not seem difficult to guess that all these figures stand for hard work combined with top of the range technology. This means that the eggs are properly taken care of at the every stage of their processing. In so doing the farm holds to Zbigniew Woźniak’s philosophy whose main tenet reads as follows: if you wish to be recognised as a reliable provider of top quality consumer eggs, they must be delicious and fresh all the year round. How do the specifics of the production process look like? Mrs. Małgorzata Kuriata, sales and marketing manager, let us on in their secret: “Once eggs are laid, they enter a line which carry them further to sorting facilities. Then according to size they are segregated by cut-
Food & Beverage IndustryFermy Drobiu Woźniak Księga1.indb 77
ting edge sorting machines which also detect breaks and place eggs into packages fit for sale. Next these are loaded onto refrigerator vehicles which deliver them to the shops around Poland and Europe as well.” State of the art production sites are furnished with BIG DUTCHMAN and MELLER cages as well as with automatic systems for moving eggs to the central sorting plant. There, top notch gears segregate eggs according to their size and place them in marketing packages.“No one touches the eggs from the moment they are laid until they are packed. This has been made possible due to the top notch solutions such as OMNIA sorting machines. Since they make sure that eggs are spotless in terms of microbiological tests, such gears are particularly sought for by the industry,” adds Mrs. Kuriata. Inside OMNIA machines there has been a special break detector installed which spots, marks and, consequently, eliminates eggs unsuitable for consumer or marketing standards. The eggs leave the storage and are loaded onto refrigerated lorries which delivered them to customers dotted around Poland and Europe. It should be added again that no one touches the eggs during the whole process, from the moment they are laid until they are packed. This has been made possible by the state of the art processing solutions. It should be added again that storage houses are air-conditioned and the temperature there does not exceed 18 Celsius degrees. Finally, a few words on transport. The management considers it crucial in the process of further growth. Needless to say, eggs are fragile and smash easily. “For that reason, we rely on our own fleet. It guarantees perfect transport conditions for our products which reach our customers intact and on time as well.” explains Mrs. Kuriata.
Eggs from Various Baskets
Nevertheless, Fermy Drobu Woźniak gained recognition on the strength of their comprehensive offer which can be roughly divided into the category of standard products (marketed in packages containing between 6 and 60 eggs) and special products processed thanks to the uniquely balanced feed blends and ground-breaking solutions. These create ambient conditions which facilitate the whole process of getting scrumptious, healthy and wholesome eggs. Royal eggs are commonly known for their XL size and it happens more
Manufacturing-Journal | 75 | 2010-04-28 14:56:16
Big Dutchman
Big Dutchman is recognized as the world leader in the most modern equipment for hen houses and pig houses. The company designs and produces feeding and drinking systems, environment control systems, cages, floor and alternative systems for poultry as well as egg collection systems. Big Dutchman offers feed factories and biogas plants. Big Dutchman Polska Sp. z o.o. ul. Sowia 7 62-080 Tarnowo Podgórne POLAND Tel. +48 (0) 61 896 28 00 fax +48 (0) 61 816 44 51 bigdutchmanpolska@bigdutchman.pl www.bigdutchman.pl
Big Dutchman jest uznanym światowym liderem w branży najnowocześniejszego wyposażenia kurników i chlewni. Koncern projektuje i wykonuje systemy zadawania paszy, systemy pojenia, systemy utrzymania klimatu w kurnikach i chlewniach, klatkowe, ściółkowe i alternatywne systemy utrzymania drobiu oraz systemy zbioru jaj. Big Dutchman oferuje także wytwórnie do produkcji pasz na fermach i biogazownie.
Marcato Sp. z o.o. Marcato Sp. z o.o. is a Polish capital company, for which the main object of activity is production of foil and food packaging. Produced in the company since 2000 year products, which are being made in the technology of the extrusion and thermoforming, are finding application in many sectors of the economy. The company is delivering its packaging to the Polish market and to countries of Central and Western Europe. Marcato customers are many highlyrenowned consumers. Our machines are line-up with new extruder and thermoforming of recognised producers (REIFENHÄUSER, KIEFEL, KUHNE, GN), production orders allowing to carry out from short to very long series. The company has a BRC / IoP certyficate, HACCP and ISO 9001:2000. For the company main areas of activity belong:
Marcato sp. z o.o. Rzakta 82, 05-408 Glinianka Poland Tel. +48 22 789 97 80 Fax. + 48 22 789 99 86 www.marcato.com.pl
•
Egg industry – the company offers the majority of types applied on the market of packaging for the chicken eggs and quail. Available packages are on form without and with the individual etiquette of the customer. Offered packages are adapted to the interaction with machines of the type MOBA and STAALKAT;
•
Meat industry – The company offers w whole range of trays, made from mono- and multilayered polypropylene foils (EVOH). Offered trays contain the absorptive input (PAD), which is attached with the technology “hot melt” or ultrasonic;
•
Gardening industry – in the offer you can find different proposals of packaging dedicated for packing vegetables, fruits and salads of different kind.
In order to get more of the information about the company and its production portfolio we are inviting to visit Marcato website or to a direct contact with a sales department. We are inviting cordially for the cooperation.
| 76 | Manufacturing-Journal Księga1.indb 78
Food & Beverage IndustryFermy Drobiu Woźniak 2010-04-28 14:56:18
Manufacturing Journal
We will surprise you !!! info@manufacturing-journal.net
www.manufacturing-journal.net
Food & Beverage IndustryFermy Drobiu Woźniak Księga1.indb 79
Manufacturing-Journal | 77 | 2010-04-28 14:56:22
afflict our herds.” This is further shown by the fact that storage houses are airconditioned and the temperature there does not exceed 18 Celsius degrees.
Market Recognition
often than not that they have double yolks. White eggs are now gaining in popularity among Polish buyers. They are as delicious as brown eggs and may also be used for decoration purposes during Easter time. Freshly laid eggs are recommended particularly for little babies and you can check when they were laid as it is stamped on their shells. Sucha a wide range of products as well as neatly designed packages has made Fermy Drobiu Woźniak earn trust and enter contracts with diverse business partners, including commodity exchanges, nationwide as well as local or regional retail networks.
Since salmonella poisoning is not that uncommon among egg consumers, you would certainly like to learn how do Fer-
my Drobiu Woźniak address hygiene related issues. The fact that the company complies with the stern requirements of HCCP food production norm should set your mind at rest, however. No matter how often their business partners, mainly retail networks, conduct an audit there, the company turns out to be impeccable in terms of safety and healthiness. No wonder, therefore, that the giants such as: Carrefour, Tesco, Biedronka, Netto, Kaufland, Intermarche, take advantage of their services. As Mrs. Kuriata stresses: “It is our topmost priority to turn out eggs of the highest quality possible. That is why we are particularly keen to make our facilities spotless and our poultry in perfect shape, which is also seen to by a full-time vet. Day in, day out, our doctor together with workers take care to prevent any health, hygiene or productivity related dangers that might
| 78 | Manufacturing-Journal
Food & Beverage IndustryFermy Drobiu Woźniak
Spick and Span
Księga1.indb 80
Mere statistics quoted so far prove nonetheless insufficient to do justice to the Woźniaks’ position on the market. There is a long list of prizes and awards, the most important being Złoty Laur Konsumenta granted subsequently in 2008 and 2009. This honour was conferred by Media Partner Group which specialises in PR for business done via printed press channels. The company prides itself also on the fact that their contribution to the making of the Polish economy has been recognised by the influential “Polityka” weekly. In the ranking ran by the magazine Fermy Drobiu Woźniak were given 355 position in general competition and 33 in the food industry category. Moreover, Regionalna Izba Przemysłowo-Handlowa (The Regional Chamber of Industry and Trade) in Leszno honoured the business for innovation in terms of technology and management. All these prizes make a strong case for the strategic marketing course chosen by Fermy Drobiu Woźniak.
2010-04-28 14:56:28
AR
TI CL E
S
THE SPIRIT OF FREEDOM
FACT BOX FULL NAME: JSC Sarmat
PRESIDENT: Igor Tikhonov
OPERATIONS: Food &Beverages
www.sarmat.ua
J
SC Sarmat is among the leading Breweries in Ukraine. Sarmat produces 8 types of beer, for almost each taste. In 2008 the world’s second largest brewery company - SABMiller Plc acquired the company’s shares and is now the main owner of Sarmat. Written by Kateryna Ferdyn. Based on the Interview with Technical Director, SARMAT JSC, John F. Cathcart.
Towards the Workers’ Needs
The construction of brewery lasted from 1952 to 1962. The history of brewery started in 1951, when Stalin, the General Secretary of the USSR, visited Donetsk mines. While encouraging miners to achieve better working results to help the country rebuild the economy destroyed by the war, Iosif Stalin asked the miners: „What would you like?”. One braver worker dared to answer: „We’d like...beer”. Immediately in 1951 the decision about constructing the brewery in Donetsk was made. Next year the project was prepared and the construction began. At that time the brewery was called Donetsk Brewery Company and was equipped with state-of-the-art machines, being the biggest brewery in Ukraine. Production capacity allowed production of 7 mln liters of beer. Traditional well known types of beer were produced, like: Zhiguli, Ryzke, Moskovskoe, Ukrainskoe. The initial enterprise employed 1100 people. Later after
modernization the number of personnel was reduced to 700, and then to 540 employees. The high quality of Donetsk beer became popular within a short period of time. The main reason for that was that beer is traditionally one of the favourite drinks in Donbass region of Ukraine, where a lot of coal mines are concentrated. Miners and metallurgists lose a lot of liquid, while working. Therefore, they should frequently rehydrate their bodies with water containing essential minerals and salts. Beer perfectly suits this purpose, as it gives energy, releases stress and replaces both the lost liquid and minerals.
Principal Changes In the mid-1990-s a full-scale reconstruction of the
Food & Beverage IndustrySarmat Księga1.indb 81
brewery was started. Donetsk Brewery always tried to be the flagship company, not hesitating to be the first to introduce innovations. Modernization helped Donetsk brewery company to be one of the first companies in Ukraine to introduce European technologies and take a leading positions among Ukrainian brewer companies. In the 1990’s Donetsk Brewery Company was the first Ukrainian brewery to start manufacturing beer in PET-bottles and kegs. Between the years 1994-1996 the specialists of the company developed the special technology of making dark malted barley, which was used to produce
Manufacturing-Journal | 79 | 2010-04-28 14:56:30
2008 SABMiller plc – the world’s second largest brewing company – acquired 99.84% of the shares of CJSC Sarmat.
Introducing Innovations to the Market
absolutely new types of dark beer that are very popular, such as Dobry Shubin. Since 1998 Donetsk Brewery Company started successfully developing the trade mark Sarmat, which in a short period of time became known far beyond the boundaries of the Donetsk region. The launch of the Sarmat trademark symbolised a new complex marketing strategy for the company, directed at gaining share of the Ukrainian beer market. The name Sarmat was not chosen by accident. It is connected with the oldest traditions of the South-Eastern areas of Ukraine, where for many years Ukrainian history was formed by strong and warlike Sarmat tribes. The Sarmats formed a nation of very proud independent and freedom-loving people. They had a unique culture, and according to legend they were the warriors of the Spirit. Their totem was an eagle, and
| 80 | Manufacturing-Journal Księga1.indb 82
it found reflexion in the Sarmat brewery symbol and main motto – the Spirit of Freedom. The Sarmat trademark soon became very well-recognized.
New Era of Development
In 2001 the brewery capacity reached 14 mln liters per year. Currently Sarmat’s market share in Ukraine is 4%. On October 27, 2001 Donetsk Brewery changed its name to CJSC Sarmat. This year became one of the most important for the company – it ended the old era and started an absolutely new chapter in the brewery’s history. CJSC Sarmat united the assets of 5 breweries: Lugansk Brewery, Non-alcoholic beer factory Krym, Dnepropetrovsk brewery Dnipro, company Poltavpivo, and Donetsk Brewery. Until 2008 the owner of 99% of Sarmat shares was the management company System Capital Management. On July 4,
In 2001 the battle for increase of beer shelf life was finally won. In this year Sarmat installed a new production line with oxygen-free bottle filling. As a result of introducing this new technology Sarmat was able to increase the shelf-life of Sarmat beers to 3 months without using preservatives or pasteurisation. That year Sarmat entered the Russian and Moldovian beer markets. 2002 was an important year for the whole Ukrainian beer industry, when Sarmat became the first and only local brewery to produce wheat beer. Prior to this wheat beer was very rare in the CIS countries, and was mostly imported from Europe. In mid 2001 wheat beer was first produced in Russia, and Sarmat did not wait long before starting wheat beer production in Ukraine. The taste of wheat beer is unique. Tasting it once, one will remember it forever. It is a light beer with a fine flavour of cloves from wheat malt, and is absolutely unique among beer types. Sarmat also created VIP beer to satisfy the tastes of sophisticated consumers. In 2002 Sarmat also introduced non-alcoholic beer, which soon found a lot of fans among car drivers, sportsmen and people leading very healthy life styles. Sarmat non-alcoholic beer has all the qualities of beer without alcohol. Until 2008 Sarmat had produced 13 types of beer under 3 brand names – Sarmat, Dnipro and Drive Max. Light beer types included Sarmat Svetloe, Zhigulivske, Originalne, Zemlak, Bavarske, Nasha Marks, Plzenske, Kaltenberg Pils, Pshenychne and alcohol free. Dark beer types included Porter, Dobry Shubin and Sarmat Temne. In spring 2009 Sarmat started producing Czech beer Velkopopovicky Kozel under licence. Sarmat entered the market with this new brand during the dynamic growth of the licensed beer market segment in Ukraine, which accounts for 9% of the total Ukrainian beer market.
Recognized by the Best Beer Authorities
The quality of Sarmat beer is proved by numerous awards obtained in national and international contests and exhibitions.
Food & Beverage IndustrySarmat 2010-04-28 14:56:39
Latest modernization improvements
In April 2009 Sarmat completed the large scale modernisation program that began in 2008. The total amount of all investments is over 140 mln US dollars. The further modernization of production equipment included installation of a special water preparation system and an advanced system of microbiological stabilization of beer. The water preparation system is specially designed to ensure that all water used in the brewing process complies with the strict SABMiller standards. As a result of the modernization of the technological processes and improvement in microbiological quality the shelf life of the beer was extended. Modernization also impacted all key business processes. New standards and systems of management, applied in SABMiller companies were implemented. Financial accountability principles, distribution as well as staff training programs meet all international requirements. Renewed Sarmat brand means, first of all, high-quality products, which are brewed according to high world standards - best natural components and international technological standards.
Product safety and brand image are vital to the bottom line. That’s why bottlers, food processors and dairy operators around the world count on Diversey for a complete range of products and cleaning systems. Our state-of-the-art offerings – including cleaning-in-place, dry technology and water hygiene and conservation systems – improve sanitation, reduce risk and lower operational costs. As the worldwide leader in the commercial cleaning and hygiene business, Diversey offers the unrivaled ability to find and implement the right solution for your business. Food & Beverage products include best chemical and engineering hygiene solutions for : • • • • • • • • • •
Beer and Beverage industry Dairy industry Meat, candy, bakery and other Process Food industries Detergents, cleaners, sanitizers, lubricants and cleaning systems Electronic dispensers and chemical injectors for the application of chemical products Gel and foam products for manual open-plant cleaning Acid and alkaline cleaners Track treatment solutions Water conservation solutions Consultation in food safety, operational efficiency and quality management
www.diversey.com 141400 Moscow region, Khimki city, Leningradskaya str., vladenie 39, building 6, Wing B tel. +7-495-970-1797 | fax +7-495-970-1798 welcome.russia@diversey.com
Food & Beverage IndustrySarmat Księga1.indb 83
Manufacturing-Journal | 81 | 2010-04-28 14:56:42
S TI CL E AR
ONE OF A FEW IN EUROPE – ONE OF A KIND
FACT BOX FULL NAME: Fabryka Osłonek Białkowych FABIOS S.A. PRESIDENT: Bartłomiej Babuśka OPERATIONS: Food& Beverage ESTABLISHED: 1973 EMPLOYEES: 500
www.fabios.com.pl
P
roducing collagen casings of high quality, Fabryka Osłonek Białkowych FABIOS S.A. is one of a few production plants of this kind in Europe. The company’s products are used in the meat processing industry, i.e. in the production of processed meat and other food products. For 36 years FABIOS has consistently widened the product range and improved production technology, thus gaining recognition and good reputation as a reliable business partner all over the world. Written by Anna Chudzik
| 82 | Manufacturing-Journal Księga1.indb 84
Starting from one type
of casings…
The FABIOS S.A. plant is situated near Maków Podhalański, in the south of Poland, on the route between Katowice and Zakopane. The company’s beginnings reach 1960s, when the first research on the casing production technology was conducted, which resulted in opening the plant and launching full-capacity production in 1973. The fist product manufactured by FABIOS was a simple, traditional type of casing, remaining the flagship product of the company until today. In the following years FABIOS developed rapidly, which was boosted by the growing demand for collagen casings from the meat industry. The company kept on launching new production lines and enlarging its premises. In the mid 1990s it introduced a new product – an edible collagen foil, which is used in manufacturing of corned and scalded products in nets such as hams. Next year, FABIOS widened the product range by offering coloured casings and casings
suitable for printing labels on the surface. Moreover, at that time the name “FABIOS” was added to the name of the company, as it had been used only on the trademark before. At the turn of the centuries, the world saw a new kind of casings manufactured by FABIOS, namely ring casings, followed 5 years later by the easily removable type. To cut a long story short, constant development and willingness to improve its products have been the company’s aspirations since the inception. After changing its legal form, Fabryka Osłonek Białkowych FABIOS S.A. is currently a state-owned joint-stock company.
Products under tight control
FABIOS collagen (protein) casings are used not only in the production of cured meats but also as packages for other foodstuffs. The FABIOS offer includes casings in various types: traditional, easily removable, ring casings and ones for raw sausages. Additionally, collagen foil for hams are produced in a form of sheets, 400 or 480 mm wide, or sleeves in calibres of 85, 115, 126, 136 and 156 mm. The main product is the traditional casing, which has been offered by FABIOS since the inception. Another type which deserves attention is the unique ring casing – in the production process it is formed into a ring, making it look like a nat-
Food & Beverage IndustryFabios 2010-04-28 14:56:47
ural casing. It is worth mentioning that only a few manufacturers can offer this kind of product. Apart from that, constant research allowed FABIOS to launch the production of easily removable casings, which are used in processed meat products intended for slicing. The offer also includes the collagen foil, and casings for the production of raw sausages such as salami. As the company admits, it managed to gain customer confidence thanks to the particular concern for the quality of products. The collagen casings are manufactured from high quality collagen fibres, obtained from healthy cattle hides. What is also of paramount importance to the quality of a final product is the careful selection of suppliers, which is why FABIOS cooperates only with the top-rank ones. In the whole production process all raw materials, as well as final products, undergo strict quality control in the company’s own laboratory. It is also common practice to have outside companies carry out specialist tests, or to commission additional quality tests. Thanks to that FABIOS can always ensure entirely safe results meeting all the requirements, while the customers can receive certificates necessary to resell casings.
How to keep the customer satisfied?
Since FABIOS perceives success as customer satisfaction, the company tries its best so as to live up to all expectations. Clients who decided to try the FABIOS products are likely to seek the cooperatation, in most cases, signing long-standing contracts. Therefore, according to FABIOS, how to keep the customer satisfied? First of all, FABIOS is open to customer’s suggestions and takes care of them, even after the purchase. From the initial stages of its activity, FABIOS has also put all its efforts into in-depth analysis of customers’ needs and market trends so as to keep pace with the growing demands. Obviously, the success would not have been possible without the company’s qualified staff. Employees from the Department of Sale and Market Analysis constantly monitor needs of the customers and check the market news. Personnel from technical and R&D sectors work on the improvement of production technology, while staff members who supervise the quality of products make sure that the casings leaving the factory are devoid
of any faults. As FABIOS admits, the staff (both those taking care of production and non-production processes), is one of the elements constituting the strategic potential of the company. Their commitment to work determines the reliability, competitiveness, and, consequently, further development of FABIOS. Another factor which helps the company build a successful brand is a reasonable price of products. In the customer satisfaction survey FABIOS was given very good mark as far as the price/quality ratio was concerned. However, in spite of the satisfactory result, the company does not want to rest on its laurels, but to achieve the highest standards and maximum customer satisfaction. Therefore, it continues to work on reducing the costs (as they determine the products price) and improving the products. To further satisfy even the most demanding customers, FABIOS invests in the development of new types of casings, which would feature the highest technical parameters. Recently, FABIOS has decided to enlarge the line for production of ring casings, since the demand for the product is greater than the company’s production capacity. The company is planning to enlarge other production lines as well. However, it is aware of the fact that all undertakings depend on the decisions of authorities supervising FABIOS, and on the financial reserves earmarked for investments. Unfortunately, simple alteration of the production line is a costly process due to the uniqueness of machines and technological solutions.
Market in Poland and abroad
Every month at least 66% od production is aimed at foreign markets, not only the European ones. The company has business representatives in France, Spain, Greece, Ukraine, Russia, Uzbekistan, Kazakhstan, Kirgizstan. Products are exported to Turkey, Armenia, Uruguay, Cuba and Venezuela. Owing to the enhancement of the production capacity, FABIOS is currently negotiating also with more countries of South and Middle America, or Asia. Within the next years the company is willing to strengthen its position on the foreign markets. Each product from the wide array of the FABIOS assortment is equally important, which stems from different preferences on the markets – Balkan markets prefer casings for the production of raw sausages, while Eastern markets – traditional casings. Polish and foreign
Food & Beverage IndustryFabios Księga1.indb 85
Manufacturing-Journal | 83 | 2010-04-28 14:56:48
markets also differ significantly, which is why monitoring clients’ needs and preferences all over the world seems so crucial for the development of the company. When it comes to the domestic market, it is susceptible to changes, making it hard to predict sales in 5 or 10 years. The situation is largely conditioned by Poles’ shopping tendencies. In the midst of the crisis people tend to consume more cured meat products of lower quality, while FABIOS casings are fit for high-quality meats. Careful analysis indicates that year by year consumers in developed and developing countries tend to eat more and more high-quality products and it is FABIOS casings which find application in their production. People prefer to buy less in return for the assurance of high quality, good taste and lack of unnecessary “refinements”. Polish market is heading into this direction as well, while other Eastern markets will join the trend in a few years. As for the former EU markets, they have already undergone this transformation.
ing plant, which makes waste management more efficient. The company can be also proud of the fact that it operates in accordance with the principles of the
parent Company (Przejrzysta Firma) certificate for the publication of financial reports. FABIOS is willing to participate in various non-business activities as well.
ISO 9001:2000 system. Apart from that, FABIOS S.A. received “Business Gazelle” (Gazele Biznesu) award four times, “Golden Company” (Złota Firma) title (granted by the Małopolskie province), or “Pantheon of Polish Ecology” (Panteon Polskiej Ekologii) award (granted under the patronage of Minister of the Environment and Director of the Polish Centre for Testing and Certification). In January 2009 the company was awarded Trans-
For example, the company has it own football team, which competes with other teams from the Sucha Beskidzka district for, among others, the cup of President of FABIOS S.A. This year the FABIOS team won the cup again. Moreover, the company is a major sponsor of numerous regional cultural or sport events and it supports various charity actions.
Sources of pride – certificates,
awards and more
FABIOS S.A. has always been associated with products of good quality offered at an affordable price. Undoubtedly, the company can take pride in various things, such as the incessant presence on the market for 36 years. The pro-active attitude, which manifests itself in the willingness to improve, develop and achieve highest quality benchmarks, guarantees impeccable taste and recognition all over the world. The efforts were also rewarded with various certificates and distinctions. First of all, since FABIOS is not indifferent to green issues, it was granted with ISO 14001 certificate for its pro-ecological activities. Situated in the area of the Babia Góra National Park, FABIOS feels obligated to protect the environment. All activities taken by the authorities are directed towards minimising the harmful effects on the environment. FABIOS possesses its own sewage treatment plant and incinerat-
| 84 | Manufacturing-Journal Księga1.indb 86
Food & Beverage IndustryFabios 2010-04-28 14:56:51
Turn your publication in the next level… www.manufacturing-journal.net
E-book it’s the feature of e-publications Convert your pdf: folder, catalogue, book, newspaper, magazine, brochure, into turn pages version.
• Cut your printing costs. • You can reach every customer who has an access to pc • Save your time • Get larger group of customers. • Wheatear you are: producer, retailer, magazine publisher, or travel agency, you will need to present your products or services in the best and most professional way, to be always a step ahead of your competitors.
Don’t be late because your competitors are always awake. Please contact us for more information and examples of our offer. e-mail to: info@manufacturing-journal.net Księga1.indb 87
2010-04-28 14:56:56
Księga1.indb 88
2010-04-28 14:56:58