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Roto Inside 25 (EN)

Roto Inside | 11.2013 12 | Editor Roto Frank AG Wilhelm-Frank-Platz 1 70771 Leinfelden-Echterdingen, Germany Editorial board Monique Gnuschke, Udo Pauly Editorial staff Comm´n Sense GmbH Lensbachstraße 10 52159 Roetgen, Germany Telephone: +49 (0)211 1730-114 Telefax: +49 (0)211 1730-123 roto.inside@commn-sense.de Design and production avency GmbH Kiebitzpohl 77 48291 Telgte, Germany Telephone: +49 (0)2504 888-0 Telefax: +49 (0)2504 888-199 info@avency.de Printing house Griebsch & Rochol Druck GmbH & Co. KG Gabelsbergerstraße 1 59069 Hamm, Germany Telephone: +49 (0)2385 931-0 info@grd.de Circulation 12,500 copies Imprint Greater efficiency with Roto Lean experts Bajcar invests in efficiency ■■ PVC In 1994, Bronisław Bajcar founded a small window factory in the northern Polish town of Słupsk, just a few kilometres from the Baltic coast. Some 20 years on, the company which still bears his name has become one of the major PVC window and door-element manufacturers in Poland. Production capacities and skills grew during this period alongside export turnover. “Nowadays, the majority of our production – 70% – is destined for export”, General Manager Gracjan Zwolak told Roto Inside. In 1994, Bronisław Bajcar founded a small window factory in the northern Polish town of Słupsk, just a few kilometres from the Baltic coast. Some 20 years on, the company which still bears his name has become one of the major PVC window and door-element manufacturers in Poland. Bajcar is one of a growing number of window and door manufacturers the world over who benefit from the services of the Roto Lean Team. This means that Bajcar uses the know- how of Roto advisers on a range of topics covering “flow production”, in other words, optimisation of opera- tional procedures in production. Rafał Koźlik and Tomasz Hejduk from the Roto Lean Team helped with their experience and recommendations to ensure an optimum integration of the frame striker assembly operation into the production flow. The Roto Lean Team consulting process kicked off at the Roto plant in Lubartów, with a presentation of best-practice solu- tions, before monitoring the following steps at Bajcar: §§ analysis of work content in the ­production §§ integration of frame striker assembly before the welding process §§ concept proposal for optimisation of sash hardware mounting Benefits for the customer: §§ improvement in process interlinking §§ rationalisation of one assembly work station §§ increased output A next step should be to integrate order- ing of espagnolettes and stay arms for the sash hardware mounting. Gracjan entered the window and door indus- try as a newcomer when he joined Bajcar in 2011; even after two years, the sheer speed of the company’s growth still leaves him in awe. “Even if you look at the figures on their own, it is patently obvious that the company has under- gone rapid growth ever since it was founded. Despite the speed, this growth was never at- tained to the detriment of substance or product quality. In fact, it’s quite the opposite: the prod- ucts and systems have become subject to in- creasingly high standards, which has opened up new markets and new groups of customers.” Today, windows and doors from Słupsk meet the most stringent EU standards and in terms of aesthetics, functionality and safety, they meet the taste and expectations of customers all over Europe. “Scandinavia, Germany, Holland, Denmark and the United Kingdom are now core markets for us, just as much as Poland is,” said Gracjan Zwolak. “What’s more, we are currently developing new systems specifically for the French and Italian markets.” Just 100 employees working in at Bajcar are responsible for a smooth-running production process which turns out an average of 150,000 windows and door units annually. Among the company’s best sellers are windows with 5-chamber profiles and triple glazing. “Although actually, we have recently seen a significant Roto Lean Modul F: Flow production Consultancy services for efficient ­window production increase in demand for our new 6-chamber pro- file systems,” said Gracjan Zwolak. Other pop- ular products are the Tilt&Slide and Lift&Slide elements for terrace doors and main entrance doors, mainly for the export market. A bastion of innovation Currently Bajcar operates two production lines: one for their normal production runs and anoth- er for making up customised designs. Glazing can be carried out on two lines. “We plan to complete our new production and warehouse complex by the end of 2014; it will be equipped with state-of-the-art production lines that will enable us to achieve an even higher degree of automation,” reported Gracjan Zwolak. However, continuous improvement processes have been in place in all parts of the company from the beginning. Regular cooperation with the Roto Lean experts is nothing but a logical consequence of this. “The first specific project that we implemented together with Roto was simplifying the strik- erplate,” recalled Gracjan Zwolak. Prior to this change, we had frequent bottlenecks and hold- ups in the workflow, particularly when assem- bling accessories such as arrestable brake stays and arrestable ventilation-stays. Together we found a solution: the strikerplate is now fitted to the frame profiles and the centre posts on the loose profile-piece. This alone enabled us to achieve a reduction in cycle times of roughly 20 per cent. Plus we were able to divert the capaci- ties freed up by this to other areas of production straight away.” Naturally, given such startling success at the beginning, cooperation contin- ued. “Together with Roto, we have developed a strikerplate standard for certified security win- dows in the RC 2 class. Glazing packers from Roto now play a central role. Working together to develop new products and efficient process- es – this is how I personally envisage the ideal relationship to a supplier.” “The first specific project that we implemented together with Roto was simplifying the strik- erplate,” recalled Gracjan Zwolak. Prior to this change, we had frequent bottlenecks and hold- ups in the workflow, particularly when assem- bling accessories such as arrestable brake stays and arrestable ventilation-stays.” Just 100 employees working in at Bajcar are responsible for a smooth-running production process which turns out an average of 150,000 windows and door units annually.

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