TOYODA GOSEI CZECH REPUBLIC
Ensuring excellence from behind the scenesÂ
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Driven by its people, plants and continues to take the automotive
Writer: Jonathan Dyble | Proje
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d products, Toyoda Gosei Czech e manufacturing market by storm
ect Manager: Thomas Arnold
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WE MAKE PRODUCTS PROUD
www.huehoco.com
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ith production levels up and investment on the rise, the European automotive industry is set to maintain an upward trajectory for the foreseeable future. A continental climate of increasing urbanisation and industrialisation, combined with a growing emphasis on improving fuel efficiency and developing autonomous technologies, has led analysts to believe that the automotive plastics market will exceed $50 billion by 2024, up from the $22 billion recorded in 2016. As a result, whilst major automotive brands are set to reap the rewards of this prosperity, so too will major suppliers and component manufacturers such as Toyoda Gosei Czech (TGCZ), a key European subsidiary within the Toyoda Gosei Group.
Plant 1 Safety Systems (SS), Functional Components (FC)
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Consistent expansion
Standing as one of Europe’s leading TGCZ’s clients manufacturers of plastic, polyurethane include, but are and rubber car components, TGCZ has not limited to: worked with a significant number of the world’s most substantial brands. Having only been established in Toyota Peugeot 2001, TGCZ’s swift rise to the top in BMW Citroën the European market can largely be attributed to its sound recognition Mitsubishi Škoda of the importance of continual VW Porsche investment. Such an attitude is reflected in the Suzuki Audi firm’s gradual facilities expansion, Nissan Daimler something that has remained consistent in the 17 years since its Honda Buick inception. Ford Subaru “Our early success as a safety system supplier in the Czech Republic led to our first plant expansion just one year later in 2002. Thereafter, we Richter, the Company’s Vice President began to manufacture a wider range of and General Manager of Corporate functional components,” explains Jan Services and HR.
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anced and stamped core metal inserts are our business. Every single day we help to ensure top results with superior production technology and a strong will to provide solutions for our customers, mainly being major Tier II automotive suppliers. Who are we? ACP (Advanced Carrier Products) has been part of the HUEHOCO Group for over 16 years. In its origins, ACP is looking back onto a history in the lancing and stamping business of well over 50 years. Our customers can therefore benefit from many years of experience in our business. Added to that is the knowhow of the entire HUEHOCO Group – a coil coating company with its own division (SIC GmbH, Wuppertal) for development and production of in-house adhesives, lacquers and bonding agents. This puts our customers in a position, where they can provide a sample of their plastic or rubber material, in order for our Group to develop a custom-made bonding agent.
With more than 165 employees, ACP is located in Germany, France, Canada, USA, Brazil, Mexico, China and also has a licence partner company in Russia. Our machinery and tools are produced centrally and developed decentrally. As a result, our various production sites are perfectly linked to each other and processes are transparent and comparable. This is a major advantage in the learning and development process in our ACP Group network, which results in very short time spans until market maturity of a new product. ACP can offer a worldwide annual capacity of approximately 600 million metres and a large portfolio within the entity of all our plants. This makes us a strong and reliable global partner for a range of different system solutions for refined metal products. Our customers appreciate the combination of quality, flexibility, thrift and service in all our sites around the world.
ACP EUROPE ACP Europe, based in Bad Salzungen (Germany) and Rethel (France), is one of the market leaders in the production and supply of core metal inserts being used for sealings and weatherstrips in the automotive sector worldwide. In Germany we are operating six automated stamping machines as well as four high speed
precision (HSP) lancing lines whereas in Rethel (France) we have three HSP lancing lines in operation and one stamping machine. This offers a capacity of more than 250 million metres per year only in Europe. In addition, since 2015, all the lancing tools for the entire ACP Group are developed, produced and maintained at our in-house tool shop in Rethel.
T +49 202 / 64 77 8 - 0 E info@acp-d.com www.huehoco.com
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LORD
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ounded in 1924, LORD has been a diversified technology leader with unique expertise in chemical material sciences which provides innovative adhesive, coating and motion management solutions. We provide long-term value to our customers’ businesses by collaborating closely with them on product design, process engineering and product performance. LORD Corporation is a privately-held company with world headquarters in Cary, North Carolina. Our company has regional headquarters in Geneva and Hong Kong, 18 manufacturing facilities, nine research & development centers and more than 100 strategically located sales and support centers worldwide.
Driver Airbag (DAB) Plant 2
“Following this, our aggressive sales strategy and the growth of the automotive sector led us to opening our second and third plants between 2004 and 2006, dedicated to the expanded production of our infamous safety systems and the manufacture of rubber sealing for car bodies.
TGCZ’s extensive production line includes: • Steering
wheels
• Airbags • Engine
covers tank components • Rubber sealing • Fuel
For more information see: www.toyoda-gosei.com/seihin
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“Since then we have remained consistent, and our recent successes have led to us working on the launch of our fourth and newest production plant that will also be purposed for the manufacture of rubber sealing.” Upon completion of the latest facility, Richter expects that TG’s total headcount in the Czech Republic alone will exceed 1,400 employees, whilst its national footprint will be expanded to a total 45,000 square metres of leading work space.
From 2016, LORD has supplied antifriction coatings and flock adhesives solutions to Toyota Gosei Czech Republic.
Determining success
Whilst both new and expanded facilities have been fundamental to TGCZ’s growth strategy, so too has been leveraging the latest industry technologies, techniques and processes. In order to maintain its competitive position within such a cutthroat industry, the TG Group readily monitors all key trends, from industry 4.0 to labour market changes, allowing the firm to continually position itself as a leading manufacturer not only within Europe, but across the globe.
T +41 22 761 50 60 E info.europe@lord.com
www.lord.com/emea
LORD Anti-Friction Coatings & Flock Adhesives With over half a century of experience in developing and manufacturing high performance products, LORD is a pioneer and world leader in coating and flock adhesive technology for automotive weatherstrip applications. LORD Sipiol® coatings and Flocksil® adhesives cover a wide range of applications and processes, serving the most demanding specifications. We understand the critical aspects of our customers’ businesses and accompany them throughout all steps of the product implementation process. Our focus on research and innovation brings cutting-edge technology and long-term value to our customers, and our technical support is widely recognized in the industry.
✓ Protect automotive sealing systems against abrasion, chemical and environmental impact, while improving aesthetics ✓ Obtain excellent noise-reduction properties for optimized passenger comfort ✓ Choose from a global solutions portfolio suited for a variety of applications, substrates and surface requirements
Other LORD Solutions for OEMs and Tier Suppliers
Chemlok® / Chemosil ®
CoolTherm®
Versilok®
Manage challenges of noise, vibration and sealing in the most demanding environments
Protect electronic components and improve thermal transfer
Enable assembly of automotive closure panels, such as doors, tail and liftgates
LORD European Customer Engagement Center +49 2103 2 52 31-0 | info.europe@lord.com www.lord.com/emea
LORD® Structural Adhesives Bond metals, plastics and composites. Replace mechanical fasteners.
Fusor ® Provide high-quality and durable repair solutions.
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BAYINDIR PACKAGING LTD
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ayindir Packaging Ltd is the youngest Company in the Bayindir Ambalaj Group, founded in 2013 in Plovdiv, Bulgaria. Its founder Mr Bayindir based the first corrugated board converting factory in 1999 in Bursa, Turkey and the Company has since expanded to include three more factories manufacturing PE and LDPE products in its portfolio. Starting its working partnership with Toyoda Gosei in 2015, the Company has to date increased its workflow in conjunction with them, indicating that the Company is on the right track. Our Goal: Further development of the European market and grow together with its customers (over 30 in Europe). Our Advantage: The will to reach where the others cannot.
Opening Trim (OT) Plant 4
“As a Group, we ensure that we track anything from key technological developments to regulatory alterations in each of the countries that we operate in, including the Czech Republic,” Richter explains. “At TGCZ alone, we are investing three to five million euros annually on new equipment and new technologies, depending on the state of the market, to ensure that we are able to adapt and accommodate new business as it is demanded.” “We also have laboratories in Japan working on various new technologies. In fact, we were awarded a Nobel Prize in 2014 after inventing a new energy efficient and environmentally friendly light source, the blue light-emitting diode (LED), one of our greatest successes to date.” Further, another of the Company’s recent invention includes e-rubber – a material that utilises electric
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currents to change the characteristics of products. “E-rubber has been developed and designed for use in robotics and biomechanics, but we believe there is also potential for its application in the automotive sector,” Richter says. Alongside this emphasis on product innovation, productive efficiency has become increasingly crucial in the modern era, something that has led to the firm financing automated manufacturing processes. “Apart from continuous kaizen activities across our production, we are working on the renewal of several production lines,” Richter reveals. “Any time such investments are discussed, we always consider how to fasten cycle times and improve ergonomics, amongst other things.” By identifying these fundamentals, TGCZ is able to tweak its strategy in a proactive manor and maintain a competitive footing across the continent.
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TIMEX makes vehicles lighter, ensure precise air and water transport in domestic appliances and meet the highest requirements of injection molding products from the clean room. For over 60 years, the Company has been a leading partner for customised and technically demanding plastic parts, rubber molded articles, elastomer parts, assemblies and systems. The Company supplies and supports leading manufacturers in the automotive, home appliance and medical technology sectors, from the ground-breaking idea through development and design, prototyping and testing to the precise production of the mature solution in series. T +49 7393 520 E marketing@etimex-tc.com
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Mitko Mitev (Financial Manager) T: +359 896 382799 E: m.mitev@bayindirpackaging.com
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TECHNICAL COMPONENTS EVERYDAY & EVERYWHERE
Petia Petrova (Coordinator&Planning&Export) T: +359 899 64 6440 E: office@bayindirpackaging.com Emre Bayındır (CEO) T: +90 224 411 1200 E: e.bayindir@bayindirambalaj.com Galin Kolev (Plant Manager) T: +359 897 626322 E: g.kolev@bayindirpackaging.com
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850 EMPLOYEES 65 YEARS OF COMPETENCE IN AUTOMOTIVE AND
3 TECHNOLOGIES
HOME APPLIANCE COMPONENTS
ETIMEX TECHNICAL COMPONENTS GmbH develops and produces customer-specific blow and injection molded parts 3D and assemblies. For over 50 years, the company has supplied leading BLOW MOLDING automotive and home appliances manufacturers with technically sophisticated, 3D seamlessly blow molded parts, plastic assemblies and rubber parts.
INJECTION MOLDING
APPLIANCES/AUTOMOTIVE CHARLOTTE NC/USA
BLOW MOLDING & INJECTION MOLDING
RUBBER INJECTION MOLDING
APPLIANCES ROTTENACKER GERMANY
MULTI-COMPONENT INJECTION MOLDING
PACKAGING DIETENHEIM GERMANY AUTOMOTIVE HRANICE CZECH REPUBLIC
HOLLOW BODY INJECTION MOLDING
AUTOMOTIVE WALTERSHAUSEN GERMANY
> Founded in 1950 AUTOMOTIVE BAD SALZDETFURTH GERMANY > 6 factories > 850 employees > Sales of €165 million/year > 5 technologies in the ETIMEX
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PETENCE IN PLASTIC AND ELASTOMER
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LEADING THE WAY IN BLOW AND INJECTION MOLDED PARTS FOR 65 YEARS
www.etimex-tc.com marketing@etimex-tc.com
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One team, one TG
For Richter, none of these developments would be available without TGCZ’s team of competent staff that he stresses are crucial in powering the Company’s progressive ambitions. “Ultimately, it is the combination of our capable workforce alongside our highly competitive products that have written the major success story of TGCZ,” he states. “We fully entrust our staff, and recognise that they have been crucial in contributing to the growth of our firm over the years gone by.” Encompassing a motto of ‘One team, one TG’, TGCZ prides itself on being part of the wider Group, a global entity that consistently maintains a high level of best practices, problem solving and teamwork throughout all aspects of its operations. “We understand the importance of employing motivated people in creating the platform to build a strong company, and this is why we consistently ensure our staff are ready for whatever we have to face in this competitive working environment,” Richter adds. A major part of TGCZ’s evolution
Jan Richter, Vice President and General Manager of Corporate Services & HR
to date has been the development of its human resources, training local staff where possible to be fully capable of operating the Company from head to toe. However, since 2017 the firm has more readily sought to hire foreign workers alongside its traditional approach due to a change in circumstances. “Central and Eastern Europe is facing major changes in the labour market, where economic booms have
EME significantly influenced employee stability,” Richter explains. “As a result, hiring experienced personnel has become even more difficult, sometimes hindering attempts to increase our workforce as we launch new programmes and products. “In the face of these changes, we have taken it upon ourselves to begin hiring foreign workers to raise our headcount to the required level.” To Richter, this ability to adapt in the face of critical situations is crucial in ensuring TGCZ’s continual progression moving forward. He concludes: “Human management is facing the biggest environmental change since 1989, and those companies that are willing to keep their head up need to find their own way to cope with these adjustments. “Our own flexibility will help in ensuring that sustainable growth is maintained in the face of this, and in five years we are hoping that TGCZ becomes the number one TG location across the whole of Europe, something we are expecting with our robust production systems continually assuring a high quality and competitive output.”
Fuel Filler Pipe (FFP) Plant 1
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TGCZ, s.r.o.; Průmyslová 2, 431 51, Klášterec nad Ohří Tel: +420 477 101 111 toyodaweb@tgcz.cz
www.tgcz.cz
www.outlookpublishing.com