"The decision to purchase this site and erect the new plant is part of our international growth strategy", declares Niklas Braun, Chairman of the Automotive Executive Board at REHAU. REHAU has been a development partner and systems supplier to customers all round the world for decades, never failing to make an impression in terms of reliability and quality. The new plant in Hungary, Mr Braun goes on to say, is state-of-the-art construction from both the environmental and economic points of view.
For AUDI, the polymer specialist has been assembling bumpers for various models at Györ since 2005, operating a 3-shift system and delivering the products direct to the automotive manufacturer's production line on a just-in-time basis. "Turning the site into our own production facility measuring more than 24,000 m² is a product of the orders for bumper systems for the new Audi TT and Q7 models, for which we need extra capacity", explains Helmut Ansorge, member of the Automotive Executive Board responsible for the globally active company's automotive plants. In future, the plan is to injection mold and paint the front and rear bumper systems for both models, as well as for the A3 convertible and coupe, at Györ, prior to assembling them locally. The exterior components for these models were manufactured in Viechtach, Bavaria, up to now. Resources at Viechtach are being used to capacity thanks to new model start-ups, so those in charge were obliged to look for alternatives. "Local production in Hungary, right at our customer's gates, brings many advantages", Mr Ansorge insists. "Because automotive sector call times are extremely short."
Apart from accommodating state-of-the-art injection molding, painting and assembly halls, the new plant located on Györ's international industrial estate also provides space for admin, fabrication, storage and logistics. But the centerpiece of the new plant is the modular painting unit based on the CO2 cleaning process. Developed by REHAU itself, this process is particularly environmentally friendly and uses no precious water resources. Predecessor plants have already proved their worth at production sites in Viechtach, Bavaria, and Port Elizabeth, South Africa.
The new production site will create up to 200 new jobs. The first assembly lines have already started up, right on time for the official start of production of the new AUDI A3 models. Around 130 people will be working a 3-shift system once the plant is officially inaugurated in autumn.