Dutch partner GevelNed visits Roto sites

Representatives of our Dutch partners GevelNed recently visited the Roto Group production site at Bad Mergentheim and our main factory and head office in Leinfelden, Germany, to experience Roto close up and learn more about the ways in which Lean production principles are applied at these sites. Roto More spoke to GevelNed managing director Ivo Würzner to find out his impressions.

GevelNed is headquartered in Zwaag in the province of Noord-Holland. Established in 1992, the company has grown to become a significant player in the Dutch window and door market, reaching homeowners via a franchise operation called Select Windows, with dealers and showrooms across the Netherlands.

Hi Ivo, can you please remind us which Roto products you are currently using at GevelNed and the main reasons for using them?

Roto NX | P tilt and turn for PVC windows and also Roto NX | Designo, the concealed hinge model. We also use Patio Alversa, including the PS Air Com version with tilt ventilation.

The main reasons for using Roto NX are that it is a very high quality product in terms of reliability and function. We also offer a long-term guarantee to our customers so it is nice when this is backed by the supplier with Roto’s 10-year warranty.

Patio Alversa makes particular sense when you are already using the Roto NX system , because it uses many of the same components. Also the functional aspects and aesthetics are very good. It ticks all the boxes.

What were your reasons for wanting to see the Roto production up close?

As Hans said, we are interested in lean operations because we are starting to implement a similar structural improvement programme. Previously I’ve done it in other industries, but obviously each industry has its own unique challenges.

Our production managers have Lean Six Sigma Green Belt training, but it is always good to be able to see inside another factory and understand the specific implementation of the lean philosophy. From Roto we wanted to learn how they involve colleagues, what hurdles they face and how they manage them.

As a factory making finished windows, the Roto Roof Windows site at Bad Mergentheim is more in line with our production, but we were also very impressed by what we saw and learned at Roto Leinfelden where the window and door hardware components are manufactured.

I wanted to get an insight into all the offerings of Roto, the functionalities and how we can make the most of these in our finished window and door products.

What aspect of the factory tour impressed you the most, and why?

Roto has formidable quality control. At the presses where components are stamped, there is an immediate check and if items are within specification, they are released. Impressive.

Sometimes the techniques are very simple but effective. For example, the use of a specially made tool so that you can check a size immediately.

What else did you notice in the production and logistics operations?

Roto is clearly improving its efficiency by thinking about how each step can first be optimised and next automated. This constant re-evaluation shows commitment to continuous improvement in ways that really make a difference.

Shopfloor management is also impressive. I like how Roto uses KPIs on a daily basis in management meetings. This provides fast feedback so they know the priorities right away and can work on them.

Logistics is clearly working well and increasingly automated, although the operation at Roto is very different to ours because we are not making components but made-to-measure products to spec. Seeing this from our customer viewpoint was a reassurance that we will continue to benefit from a reliable logistics performance, but not as relevant in terms of us learning from it.

Which products or solutions in the showroom caught your attention, and how do you see them fitting into your market?

We want to position ourselves above our competitors, especially in terms of aesthetics and function. Concealed hinges are a very powerful benefit and we want to make this standard across our range. Obviously we were impressed by Roto NX | C window hardware because of the flexibility, minimal number of different parts and unique functions like TiltSafe.

We discussed which systems to use for heavy windows with triple glazing and Roto NX | C covers a lot of requirements here.

Also, sliding doors – we want to adopt the sliding system from Schüco that uses Roto Patio Inowa, so we will get the best quality all round, especially with the advantages of strong weathersealing and smooth operation.

Were you able to give Roto any feedback on what you would like to see in future?

Sometimes it is difficult to find a simple solution for electromechanical locks. The industry sometimes makes products too complex. This is feedback we provided to Roto.

What benefits do you expect to get from what you learned on your Roto visit?

We just finished a quick meeting with an external consultant who supports us in our own lean programme. We now have an action plan: amongst others focusing on quick changeovers using the SMED approach. This will help us switch from making one product to another in a faster and more efficient way.

Having seen lean production operating at a high level at Roto has provided us with a powerful example, including how to involve colleagues and spread enthusiasm in the whole organisation.

What does this visit mean for the future of your partnership with Roto?

I think on one hand, the adoption of lean and process optimisation can be done together. There is some potential for joint optimisation. Innovation is also vital — it can be very fruitful if you have discussions about market potential. These two fields are very suitable for further co-operation.

I would like to thank Hans and everyone in the Roto organisation who planned this visit and who took us around and answered all our questions. It has been very valuable for us.