Our family business is defined by the constant improvement from the beginning. With our continuous developments and with broadening our applied technologies, we keep on meeting the demands of our partners.
Our customers expect a high technological level, strict high quality in production capacity, and an ever-growing product portfolio, which we successfully meet while growing our efficiency. Our successful efforts are proven not only by the expansion of our factory and plant, and by the growing numbers of our employees but by the honorable recognition’s of our partners.
Our goal is to utilize our experience we acquired from before we’ve even established the company in 1993 to continue on the road and keep our decisive role in Hungary’s automotive industry. Our primary concern is for our products to create a sense of security and trust in our customers and to send a message of comfort and aesthetics.
1988 THE BEGINNINGS…
Our business was born in the village of Fajsz, in our family home’s garage. In the beginning, the members of our family along with a couple of employees were producing parts for agricultural machines and metallic parts for bedframes.
1993 ESTABLISHMENT OF THE COMPANY: FROM INDIVIDUAL PROPRIETORSHIP TO COMPANY
With the first and second generation joining forces our family business grew into a business company. We have been TIER 1 suppliers of the Hungarian Suzuki since the establishment of their factory in Esztergom in 1992. Through our well-balanced collaboration we got to know the Japanese working ethic, efficiency, and KAIZEN, that we later applied and further developed in our own production.
2001 THE BIG STEP: ESTABLISHING A NEW FACTORY
Because of the growing numbers of orders and the growing requirements in quality, we could not delay a complete renewal any further.
On the paprika field at the border of Fajsz, mostly out of our own resources, we have built a 1600 m2 floor space factory hall and a two-story office as a greenfield investment.
As an upgrade to an already up-to-date shop floor in means of labor safety, production, and technical demand, we were able to produce parts at a higher capacity on our smaller-sized and less powerful press machines and two welder-rooms.
2004-2005 PROGRESSIVE PRESS HALL AND WAREHOUSE
The first hall in our new factory-ground satisfied our capacity needs for three years, but we had to follow up on the increasing number of orders, so an expansion was due.
We bought new fields, which allowed us to expand our shop floor: in 2004 we built a 700 m2 floor space hall for progressive presses, then in 2005 an also 700 m2 floor space warehouse.
2007 BIG MACHINE HALL AND CANTEEN
After three years we could finally execute our old plan: we built a 700 m2 floor space warehouse for logistics and a 1200 m2 floor space factory hall. There we could place the company’s pride and joy at the time: a Japanese KOMATSU 200 metric tons servo press and from the Italian ZANI SPA 300, 400 and 500 metric tons presses tailor made for us.
To serve the ZANI presses, we planted robotic manipulators, which can be viewed in the short film made by Flexman Robotics in our factory.
The increasing number of our employees inspired us to build a canteen, where we made sure to place a functional kitchen and a dining room.
2010 INTODUCING ROBOTIC TECHNOLOGY: POINT WIELDING ROBOT CELLS
Back in 2009 as an experiment, we started using a YASKAWA MOTOMAN spot welding robot. We were soon convinced that it produces better quality parts, much faster in mass production.
With the introduction of robotic technology, proved to be a success, so we decided in 2008, defying the economical crisis, which hit our country, especially the automobile industry hard, to make a brave move and we built a 600 m2 floor space welding hall where we could use automatic resistances a and we pulled into production two new YASKAWA MOTOMAN wielding robots.
2012 CUTTING EDGE TECHNOLOGY: CRANED ZANI HALL – MAINTENANCE
The Japanese KAIZEN means: every hardship, every challenge also creates an opportunity for progress. Following this train of thought, trusting in the recovery of the economy after the global crisis, in 2011 we decided that we have to invest in a technologically more advanced hall. Our plans became reality at the end of 2012: we built a 1000 m2 floorspace, 11 meters high factory hall, which we named ZANI Hall after the ZANI presses located there.
Besides the 500 tonnes press, we already had, we bought a 400 tonnes press, a 500 tonnes press, a 630 tonnes press, and a 1200 tonnes press. With these new ZANI presses, we could now produce bigger, more complicated parts.
Our main focus was purchasing other high capacity and big tabled presses, alongside with robot-manipulators and transfers.
Short video about the plant opening ceremony from CNCMedia:
The presses are served by a 12,5 tonnes carrying capacity crane, and a waste-carrying strip in the foundation.
Also from this year in our small factory next to the family home, we started to produce and assemble electric window parts for the SUZUKI Vitara and SX4 S-Cross as suppliers of JOHNAN UK.
2017 WAREHOUSE UPGRADES – TRANSFER TECHNOLOGY
We turned the canteen that was handed over in 2007 into a communal place featuring breathtaking architectural elements. We finally had a spacious ballroom, creating the perfect environment for important events in the company’s life.
Our highly valuable manufacturing tools are regularly maintained and kept in a safe environment, so we can assure the most cost-effective and high-quality products all the time. This would be impossible without our professional colleagues and adequate storage.
To be able to move and store these dies safely, around 2015-2017 we started using running cranes in our new 680 m2 floorspace hall.
Not to replace the human workforce, but to do the heavy labor in a constant and effective way, we decided to upgrade our two ZANI presses with two Italian NORDA SPA transfers, which moves the parts between workstations, which helps to increase the press’s efficiency.
This year we purchased a 630 tonnes capacity ZANI press
2017 HIPA INVESTOR OF THE YEAR – SUPPLIER OF THE YEAR
Under the operation of the Hungarian Department of Foreign Affairs and Trade, the Hungarian Investment Promotion Agency ( HIPA) gave us the honoring award of „Investor of the Year 2017 – Supplier of the Year”. The Agency thanked us for being a 30-year-old family business and the work we put into the automobile industry in the last 25 years.
2019 TECHNOLOGICAL UPGRADE – LASER CUTTING, ARC WELDING AND DEEP DRAWING
What we have learned in the past three decades, is that besides the press and wielding of automobile parts, we have to incorporate new methods into production.
During these years of work, the demand for cutting and bending metal sheets came back in an increasing number.
After long planning, we put together the design of a new hall with new machines, that we successfully executed in barely a year – partly by our resources, partly by tenders.
Our new 580 m2 hall is equipped with the newest air changing technology, with a 12 tonnes capacity running crane, two FANUC spot welding robots, one FANUC arc welding robot, a SALVAGNINI laser cutting machine, and a SALVAGNINI bending machine. We also put four inverter welding machines and a 3D precision measuring lab here.
The parts for the new hybrid cars are being produced and assembled in this hall. In addition, we produce large car-body parts that require special expertise and safety here.
To be able to produce these complicated parts, we purchased a new GALDABINI hydraulic press this year.
2020 QUALITY AND ACCURACY: PACKAGING HALL AND ENTERPRISE RESOURCE PLANNING
Due to the positive developments in our production capacity in the past three years, our packaging facilities had to be expanded.
Our lack of safe and reliable packaging space now threatened the punctuality and the quality of our products.
It was in our best interest to solve and minimize this risk. Facing the restrictions of COVID-19 in Hungary we successfully built a 530 m2 packaging hall, with shelves that can secure 180 containers. Here we can safely store the new large metal parts until shipping.
To keep up with the industry’s strict regulations regarding product safety and quality we developed a new laboratory for measuring the parts we produce, including the arc welded parts.
This year our company successfully set up a new ERP, so we could monitor the planning of production, inventory, labor affairs and finances more effectively and securely.
Also this year, we further developed our robotic welding technology and capacity by installing two FANUC spot welding cells.