The factory in Bratislava has been in development since 1970, however final assembly of vehicles has only been conducted between the years 1982-1986. About 3700 vehicles left the production line, however major quality defects were present. Source: Matador Group.
The cooperation between Volkswagen and FBE dates back to 1993. Starting that year, Volkswagen has expanded its newly acquired plant in Bratislava. Beginning with the production of just a few vehicles per day, Volkswagen has decided to work with FBE. This decision was understandable, as at that time FBE has already supported automotive suppliers, such as the company Sachs (today ZF). FBE could provide know-how that Volkswagen could use.
The first Volkswagen produced in Bratislava was the Passat. Source: Volkswagen Slovakia website.
BEGINNING OF COOPERATION: 1993
Quote of Jaroslav Holeček, Board member, Volkswagen Slovakia:
"Volkswagen Slovakia a.s. has been working with FBE since 1993. This company prepares and provides trainings for us in a variety of areas, notably in improving quality and effectiveness, statistical methods and team based problem solving methods. Apart from the trainings, this company also cooperates with us on direct implementation of these methods into our processes. Since 1996, we are jointly implementing a project of analysis and expansion of the organisation culture."
Quote from Andrea Tuchznova, HR Entwicklung der Firma Schaeffler:
"Die Firma FBE hat unsere Anforderungen immer sehr flexibel und professionell behandelt. Die Feedbacks der Teilnehmer nach Schulungen, welche durch diese Firma realisiert wurden, sind besonders positiv. Sie deuten auf eine proaktive Vorgehensweise, auf ein qualitätsvollen Lektoren Team, effektive und dabei unterhaltsame Methoden bei den Soft Skills hin. Bei den Fachschulungen wie Projektmanagement und statistische Methoden der Prozesssteuerung schätzen wir die fundierten Lektoren, Anpassung an unsere Bedürfnisse und auch Vermittlung vieler fachrelevanten Informationen hoch. Diese Gesellschaft gehört langfristig zu den bestbewerteten Lieferanten der Schulungsaktivitäten."
The first topics were process management and statistical methods of process control (SPC). Back in 1998, the factory was able to evaluate the paint quality at 200 points per vehicle using EDP. As the plant in Bratislava continued to grow, so did the cooperation between Volkswagen and FBE. Implementation of Idea Management (Kaizen, later CIP and KVP2), but also topics such as PDCA workshops, risk analysis FMEA, 8D, auditor development and many others followed shortly. Volkswagen was aware, however, that competitiveness cannot be guaranteed without their supplier network. For this reason, FBE also supports many of VW's key suppliers, such as Continental, Bosch, Grupo Antolin, Brose, Magna, Faurecia, Johnson Controls, Hella, Plastic Omnium, Hörnlein, Siemens, Magneti Marelli and many more. (Clients of FBE).
UNTIL 2000: BROADENING OF COOPERATION. MORE THAN 15 SUPPLIERS DIRECTLY SUPPORTED.
Quote from Gabriel Karpaty, Qualitätssicherung-Karosseriekaufteile, Volkswagen Slovakia: “APQP/PPAP von FBE hilft den Teilnehmer den Qualifizierungsprogramm "Formel Q Neuteile" zu erfüllen. Mit Konzeptphase startend, durch Produkt und Prozessplannung, Implementierungsphase, Lastenheft und Sortierung der 2 tägigen Produktion, bis zum Erreichen der qualitativen und quantitativen Anforderungen für Kaufteile des VW Konzerns.”
Quote from Martina Lojova, HR development der Firma ZF:
"Zur Zusammenarbeit mit dieser Gesellschaft würden wir gerne ergänzen:
Flexibilität, faires Handeln und Professionalität – das sind die Prioritäten, welche unsere Zusammenarbeit erfüllt und deswegen arbeiten wir schon mehr als 10 Jahre mit der Firma FBE zusammen."
Already in 2000 Volkswagen Slovakia was one of the best Volkswagen Group plants worldwide. It was decided to further expand the plant and also to build the subsidiary plant for component production in northern Slovakia. Apart from these two plants, FBE also supported the giant Skoda plant in Mlada Boleslav.
The cooperation between Volkswagen and FBE continued, among other things, with the introduction of the Group Production System in 2007-2008, with more than 8,800 employees trained within one year. The successful implementation of both, the production system and the implementation of other methods such as shopfloor management, analytical methods or specific quality topics, has been reflected in many international awards. In 2011 Volkswagen Slovakia received the European Lean Award in the category OEM as the first company from the former Eastern Bloc.
2000-2010: GROUP PRODUCTION SYSTEM.
SUPPORT FOR 3 PLANTS AND OVER 30 SUPPLIERS.
Quote from Dagmar Wittgruber, Personalentwicklung Leiterin, Volkswagen Slovakia:
"FBE Schulungen und Projekte sind einfach anders. Alles ist interaktiv und sie verbinden die neusten Trends aus dem Bereich Lean Production und Qualitätsmanagement mit Beispielen direkt aus unserem Werk. Sie haben uns vielmals die Augen geöffnet. Sie haben uns geholfen die Prozesse optimal zu gestallten und die Mitarbeiter zu überzeugen, dass auch in so einem renomierten Unternehmenwie Volkswagen, können wir die noch besser und effektiver werden."
Quote from Martin Liebl, Sales Director, MIBA Steeltec:
"Die von FBE benutzten Methoden haben bedeutend zu unserem Verständniss von Problemlösung beigetragen. Messbare Benefite der Implementierung von standardisierten Methoden Six Sigma und Lean Managements sind offensichtlich sowohl für unsere Black Belts, Green Belts, als auch für unser Management Team."
These successes have further motivated Volkswagen, so that in 2013, after a yearlong preparation, the next wave of production system training has been started. This time, the program and subsequent implementation focused on specific topics such as flow, precision, and ergonomics, which then enabled the many new production launches throughout the coming years. Subsequently, FBE also participated in the leadership development programs, in the numerous risk analyses for the new production, or in value stream analyses.
This is what production in Volkswagen Slovakia looks like today. Picture shows the so-called wedding in the production of Audi Q7. Source: Official picture gallery of Audi.
SINCE 2010: EUROPEAN LEAN AWARD.
GROUP PRODUCTION SYSTEM II.
SUPPORT FOR OVER 40 SUPPLIERS.
Quote from Mariana Mlcuchova, Personalentwicklung Manager, Volkswagen Slovakia:
"FBE ist ein professioneller Partner bezüglich Schulungen und Beratung, empathisch bei Verarbeitung der Kundenbedürfnisse, kreativ beim Konzipieren der Maß geschnittenen Schulungen, anspruchsvoll zu eigenen Beratern und Lektoren, mit Kapazität auch die komplexen Projekte umzusetzen. Dank diesen Eigenschafften sind die Projekte und Schulungen von FBE bei Volkswagen Slovakia effektiv und immer nachgefragt."
Quote from Christophe Baptiste, General Manager, Getrag Ford Transmissons:
„The investment to Lean Management and Six Sigma programms showed to be one of the best investments our company could do. Our people changed their thinking. They are better prepared to come with solutions enabling us to beat our competitors."
At the end of 2018, Volkswagen Slovakia was the largest private employer in Slovakia with 14,800 employees. With a turnover of 10.38 billion euros, it is the largest Slovak exporter and taxpayer. And with 5 brands under one roof, Volkswagen Slovakia was the plant with the largest production complexity in automotive worldwide.
FBE is proud of the success achieved through cooperation with Volkswagen and its suppliers.