THE FABRICATOR

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WINDOW HARDWARE World class in Hungary “Always bigger,always more modern, always better and always more efficient,” is how plant general manager Ernö Kocsis (pictured right) described the near 20-year history ofRoto’s plant in Lövö,Hungary The Lövö factory isthe Roto group’s largest production facility worldwide. Of the 140,000m 2 site the manufacturing and storage area,occupies 28,300m 2 with the administration area and the new showroom occupying an additional 1,400m 2. . The Lövö factory manufactures tilt-and-turn, turn-only and tilt-only window hardware as well as special opening types, such as tilt-andslide. Roof window gear is also produced in Lövö. Continuous investment Ernö Kocsis says that continual investment at Lövö has seen expansion and modernisation in both buildings and plant and equipment. In 2007, an assembly hall was added, in 2008 araw materials store, in 2012 a press department and in 2013 a finished goods store with five racks all equipped with advanced production and logistics technologies. Tool making An important part of the operation is tool production and maintenance. Around 50 staff are responsible for the production of new tools and replacement parts as well as repair and maintenance of around 4,000 punching tools. The in-house product design department, with 15 employees, works in close cooperation with the design department at headquarters. The department makes tools for the whole Roto group and there is an intention to supply to outside companies as well. The machines at Lövö are maintained on apredictive, total maintenance system. This largly 28 Roto consolidated production group’s largest production location. 140,000m 2 in Lövö, Hungary One of two punching halls in Lövö: these house atotal of 16 fully automated presses and six reworking presses Around 4,000 different hardware items run off the Roto production lines in Lövö. aAbout 50 million products every year obviates breakdowns with machines being taken out of production for servicing according to aschedule. World class The plant operates on aworldclass manufacturing principle. Problems are discussed at regular meetings and progress of solutions is charted. In the production department 16 fully automated presses and six reworking presses with atotal compressive force of 67,000 kN are housed in two halls.Between them they machine 15,000 tonnes of steel and produce about 120 million punched parts a year. Electroplating is outsourced to Sopron which carries out surface treatments with ‘Roto Sil’ and zinc nickel coatings. Assembly From the semi-finished product store intralogistics maintain the Kanban system which supplies the assembly stations. In assembly there are three high volume, small volume and concealed hardware production lines. Roto uses fully- and semiautomatic machines at single workstations and assembly islands to manufacture about 4,000 different hardware versions.Overall this amounts to around 50 million pieces every year. Despatch and delivery key The plant does not manufacture for stock. The ambition is to deliver its output. “This,” says Kocsis, “is vital for customer stisfaction.” With a capacity to handle 7,000 pallets the plant sends out 1,200 truck loads every year. ❐ www.roto-frank.co.uk The Fabricator 2015
www.firmanglass.com www.firmanglass.com Glass Excellence Established in1975 Firman Glass isone of the leading independent glass processors inthe UK, manufacturing toughened glass, laminated glass and specialist sealed units. Based inHarold Wood Essex within 5minutes of junction 28ofthe M25 and half an hour from Central London we are ideally situated to service our ever growing and diverse customer base. Manufacturing all forms ofprocessed toughened glass, with comprehensive stocks of clear float, low iron, satin, body tinted, mirrors, laminated glass, acoustic laminated and fire rated glass. With some ofthe most advanced capabilities in place Firman Glass isable tomanufacture high quality products for all markets sectors including architectural, retail, leisure and domestic. roducts Toughened glass Processing CNC shaping Laminated glass Toughened and laminated constructions EVA and Vanceva coloured interlays Fabric and decorative interlays Saflex DG41 structural interlay pplications Structural glazing Glass floors Partitions Roof lights Balustrades Full height barriers Canopies • Specialist insulating glass units • Anti–slip glass • Fire rated glass • UV bonding • FIRMALITE electric switchable glass • Heated glass • Decorative glass • Sandblasting • Colorfirm TM back painted glass • Staircases • Treads and stringers • Shower screens • Shelving • Glass doors • Acoustic reduction • Fire rated • Decoration • Wall cladding • Splashbacks • Privacy • Technical Support • Nationwide Coverage urther information isavailable from our sales and technical offices or visit www.firmanglass.com irman Glass,19 Bates Road, Harold Wood, Romford, Essex RM3 OJH el: 01708 374534 Fax: 01708 340511 Email: sales@firmanglass.com
Page 1 and 2: DECEMBER 2015 THE FABRICATOR Commer
Page 3 and 4: THE FABRICATOR Contents News -4-10
Page 5 and 6: Sawing and Machining asit should be
Page 7 and 8: CONVERT YOUR XISTING BUSINESS INTO
Page 10 and 11: NEWS Realities &future Welcome, ins
Page 12: NEWS Business day out Efficiently M
Page 15 and 16: endless light Lumi. The new seamles
Page 17 and 18: PVC-U SYSTEMS Growth for investment
Page 19 and 20: ++ A A ++ A + A B C D THE FIRST A++
Page 21 and 22: ALUMINIUM -CAB’S YEAR CAB members
Page 23 and 24: Designed and patent pending in the
Page 25 and 26: GLASS &STRUCTURAL GLAZING Asmooth c
Page 27 and 28: www.glass-handling.co.uk Specialist
Page 29: Roto TSL The TSL, from Roto is a tw
Page 33 and 34: Read The Fabricator on-line at: www
Page 35 and 36: PROFINDER www.profinder.eu Tel: 078
Page 37 and 38: PROFINDER www.profinder.eu Tel: 078
Page 39 and 40: Top agency design but not the cost

THE FABRICATOR

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