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 honourable recognitions 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 good usability, comfort and aesthetics.
Our business was born in the centre of 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 furniture fittings in small series.
With the first and second generation joining forces our family business grew into a business company. We have been TIER 1 suppliers of Magyar 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.
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.
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.
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 installed robotic manipulators, which can be viewed below in the short film made by Flexman Robotics in our factory.
The increasing number of our employees inspired us to build a central canteen with a dining room and a hot kitchen.
Back in 2009 as an experiment, we started using a YASKAWA MOTOMAN spot welding robot. We were soon convinced that on parts that are difficult to handle by human strength, it performs the spot welding of our mass-produced products more accurately, in better quality and, not least, more efficiently.
The introduction of robot technology brought encouraging results, so, defying the economic crisis that has hit Hungary, and the automotive industry in particular, hard since 2008, we took a bold step and built our welding hall with a floor area of 600 m², in which, alongside automatic resistance welders, we put two further new YASKAWA MOTOMAN welding robots into operation.
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 economic 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 further high-capacity presses with large bed sizes, as well as robot manipulators and transfer equipment.
The machines are served by an overhead crane with a lifting capacity of 12.5 tonnes and a scrap conveyor system recessed into the foundation.
Short video about the plant opening ceremony from CNCMedia:
Also from this year, in the cradle of our company in the centre of Fajsz, in our factory next to the family home, we started to produce and assemble the rear electric window regulators for the SUZUKI Vitara and SX4 S-Cross passenger cars as a sub-supplier of JOHNAN UK.
Based on the experience gained over our three decades of operation, we recognised that, beyond pressing and welding technology, we also have to open up to further metalworking methods in the production of passenger car parts.
In the course of our work, the demand for cutting and bending metal sheets arose more and more often, and our customers also pressed for it. After long planning, we put together the design of a new hall with new machines, which we successfully executed in barely a year – primarily from our own resources, partly with grant funding.
Our new 580 m² hall is equipped with the latest ventilation system, with a 12 tonnes capacity running crane, two FANUC spot welding robot cells, one FANUC arc welding robot, a SALVAGNINI laser cutting machine, and a SALVAGNINI press brake. We also put four further new inverter welding machines here, and to ensure quality we relocated our precision 3D measuring lab here.
For the hybrid cars that our most significant partner, Magyar Suzuki Zrt., put on its production lines this year, we already produce and assemble the battery and converter holders in this hall. In addition, we produce large car-body sub-assemblies that require special expertise and safety here.
To be able to produce these special parts, we purchased our first new GALDABINI hydraulic press this year, with which we can also perform press operations that we previously did not use for lack of suitable equipment.
Due to the positive developments in our production capacity in the past three decades, our packaging facilities for daily shipment proved to be insufficient.
The lack of space was already jeopardising the safe dispatch of finished products to their destination on time and in the required quality.
It was in our best interest to minimize this risk in order to ensure the conditions required in the automotive industry. Facing the restrictions of COVID-19 in Hungary we built a 530 m² packaging hall, with shelves that can hold approximately 180 containers. Here we place the new complex and large parts we have taken into production in containers and store them until shipping.
To keep up with the industry’s strict requirements regarding accuracy, product safety and the sale of defect-free parts we are setting up a new measuring laboratory, among other things for the inspection of our arc welded parts.
Thanks to the integrated enterprise resource planning (ERP) system our company successfully introduced this year, up-to-date records covering everything from production planning and inventory to HR and finance guarantee the security of our data and processes.
Also this year, we further developed our robotic welding technology and capacity by installing two FANUC spot welding cells.
To meet the customer requirements that have arisen at a higher level, we built a production hall with a floor area of 1 200 m², equipped with environmentally conscious and energy-saving solutions, together with the necessary welfare block.
This hall houses 4 FANUC resistance welders and one FANUC arc welding robot. In order to provide the parts to be welded together on the robots with fasteners, we installed 5 pedestal resistance welders and one stud welding machine.
Inside the building we have also solved the container storage of the semi-finished and finished parts manufactured here.