Professional Documents
Culture Documents
Engine of Growth: The Automotive Industry in Hungary
Engine of Growth: The Automotive Industry in Hungary
Engine of growth
Dont Bnki (1859-1922) and Jnos Csonka (1852-1939) were the joint pioneers of engine manufacturing in Hungary. They applied for a patent for the petrol engine in 1888 and the carburettor in 1893. In 1894, Bnki patented his high-pressure combustion engine and upgraded it with injected water cooling. Csonka constructed the first Hungarian gas motor in 1879 with tools and equipment he devised himself. In 1882, he built a blended fuel gas and petroleum motor. Csonka has been credited with a host of original inventions, including various measuring devices, a motor tricycle and, in 1905, a transport vehicle for the Post Office. The latter marked the birth of the Hungarian car manufacturing industry. A journalist, office clerk, sculptor, and painter in Budapest, Jzsef Lszl Br (1899-1985) is best known for inventing the ball-point pen. However, when he found his newly-bought Bugatti's clutch mechanism too unweildy, he tinkered around for a year, before making and patenting his own automatic gearbox. General Motors offered him half a percent of the price of each unit sold and a monthly $200 advance for five years. The advance secured him an easy life for a while, but the licence fee was never paid, as the American company suppressed the patent and sank it to the bottom of a filing cabinet. Jen Fejes (1877-1952), largely forgotten today, was the first man in the world to submit patents for manufacturing automobile parts by cold-forming, pressing, torch- and spotwelding. From 1911, Fejes, a constructor at the Hungarian General Engineering Co., replaced all cast and heavy pressed
The gearbox
Why Hungary?
iron parts with cold-formed parts and steel plates. Cold forming allowed the use of steel plates of vastly reduced thickness, slashing the dead-weight of vehicles designed by Fejes by 30 to 35 per cent. One of the most talented technical forebears of the American automotive industry, Jzsef Galamb (18811955) began work at Ford in December 1905. The Model T designed by Galamb was ready by 1908 and 19 thousand cars were sold the following year. Its most important part was the planetary gearbox, one of Galamb's most brilliant inventions. Jzsef Galamb also designed the world-famous Fordson tractor and the ignition plug. Bla Barnyi (1907-1997), the father of passive safety in automobiles, was employed by Austria-Fiat, Steyr and Adler (predecessor of Audi) before joining Daimler-Benz in 1939. Heading the pre-development department of DaimlerBenz from 1939 to 1972, he developed the concept of the crumple zone, the non-deformable passenger cell, the collapsible steering column and many other safety features of Mercedes-Benz automobiles. He is also credited with having conceived the basic design for the Volkswagen Beetle in 1925, five years before Ferdinand Porsche claimed to have completed his version. Barnyi was nominated for the award of Car Engineer of the Century in 1999 and inducted into the Detroit Automotive Hall of Fame in 1994. Dr. Ferenc Anisits (1938- ) was one of the founders of the BMW Diesel Development Centre in Steyr, Austria. Anisits developed a new four-cylinder engine which debuted in 1998 at the 24-hour race in Nurburgring. The 3-Series BMW outperformed its petrol-driven rivals, making it the first victory for a Diesel-powered car. At BMW, Anisits developed the V8, the world's first direct injection Diesel engine. This and a six-cylinder version were awarded the title of International Engine of the Year in 1999 and 2000. Anisits has developed three generations of Diesel engines at BMW. Ferenc Pavlics (1928- ) developed NASA's Moon Rover, the first vehicle in history to travel on extraterrestrial terrain during the Apollo 15 expedition of 1971. Pavlics's engineering background included six years of machine design in Hungary. After the 1956 uprising, he left the country and was involved in research and development at General Motors from 1960. Twenty-seven years of service for GM included engineering and management positions in vehicle mobility research, advanced vehicle design, lunar surface vehicle projects, and electric propulsion systems. Pavlics designed and supervised the manufacture of mobility test equipment, instrumentation and experimental vehicles and, as Project Engineer for several NASA contracts, also designed manned and robotic surface vehicles. The rover, known as Newcomer, was improved by NASA under Pavlics's direction, and landed on Mars in 1997 with the Trailfinder space probe.
Whether you are a producer looking for a cost-effective manufacturing base, competitive component and part suppliers, or locations for logistics and R&D centres, Hungary has plenty to offer. Hungary is at the heart of Central Europe, a region characterised by dynamic economic growth driven by high industrial output, excellent export potential and increasing domestic demand. Hungary lies along the Eastern border of the EU and is within the Schengen zone. The country's strategic position, highly developed logistics and utilities infrastructure and traditional role as a trading post makes it increasingly important as a regional distribution centre and a natural service hub for the CEE region. Four trans-European motorways run through Hungary, more than in any of the neighbouring countries. Most countries in the Balkans can only be reached through Hungary. As a member of the European Union, Hungary has fully harmonised its legal system, adopting European safety and quality regulations related to automotive manufacturing. Hungary also compares very favourably when it comes to data security and enforcement of intellectual property rights. Highly skilled, creative and flexible human capital at competitive cost: companies can expect a 30-50% cost savings compared to Western Europe and the US. The average gross wage in Hungary is just EUR 747 per month while labour productivity is among the highest in the CEE region. The Hungarian labour force also rates highly in international comparisons for innovation and creativity, due to the country's renowned standards of schooling and tertiary education. Fourteen of the world's top 20 Tier 1 suppliers, including Robert Bosch, ThyssenKrupp, Denso, Michelin, Valeo, Bridgestone, Magna Steyr, Borg Warner, Visteon, Delphi, Continental, Lear, Siemens and Sumitomo are already present in Hungary. They have also surrounded themselves with clusters of home-grown small and medium-sized manufacturers and service suppliers. Renault-Nissan, General Motors and Porsche have chosen Hungary as a location for part centres supplying not only the Central and Eastern European markets but also Ukraine, Russia and the Balkans. Business processes have been simplified considerably in recent years. In addition, foreign companies willing to settle in Hungary are welcomed with comprehensive trade development services and supportive government policy. Hungary has a globally recognised academic and university infrastructure. Increasingly, automotive-related R&D activity is carried out in top universities and research institutions, while leading global manufacturers, including Audi, Bosch, Knorr-Bremse, Magna-Steyr and ThyssenKrupp, have established R&D centres in Hungary. Hungary is the regional leader in the production of petrol engines and the fourth largest exporter in Europe.
Driving innovation
R&D in the heart of Europe
04 05
Globalisation has encouraged multinational car companies to outsource an ever-increasing proportion of product development to local small and medium-sized enterprises. This is possible only when these suppliers are able to harness their innovative power while effectively integrating their R&D activity into that of their international partners. Government programmes can help Hungarian SMEs catch up to industry leaders, partner effectively with multinational firms and integrate their activities into international supply chains and R&D systems. This can be done partly through the government's supplier incentive programme, and partly through a plan to extend the network of Automotive Competence Centres to complement Regional University Knowledge Centres currently operating as R&D bases. The goal is to spur innovation and R&D through efficient collaboration between multinational companies, supplier SMEs, academic research institutes and other relevant organisations. This policy aligns well with the EU's development plans for the present budget period, and with the aims of the 7th Research Framework Programme (FP7). In the interests of encouraging innovation and nurturing R&D talent among SMEs, the Association of the Hungarian Automotive Industry has established a strategy for Automotive Competence Centres. The Automotive Competence Centres: Create a knowledge network for national and international R&D collaboration Hone companies' aptitude for innovation by promoting knowledge and technology transfer Act as an incubator to SMEs by offering an expanding range of business services to meet specific needs Engage in collective marketing activities on behalf of members and with other institutions Serve as a centre for the collection, processing and presentation of member information via the Internet and related technologies.
Key statistics
Production: EUR 15.9 billion, Export: EUR 14.3 billion Export ratio: 90% Skilled workers' average gross wage: 444 EUR/month Share of foreign capital: 75% Distribution of companies by ownership: Domestic: 52%, Foreign: 23%, Joint venture: 25% Share of total national exports by Audi, Suzuki and GM Powertrain combined: 11% Number of automotive manufacturing firms (OEM, Tier 1Tier 2): 630 Number of automotive manufacturing firms with audited quality-assurance systems: 240 Number of employees: 110,000 Proportion of employees involved in main-unit manufacturing: 12% Proportion of employees involved in part-unit manufacturing: 88%
Automotive research
Audi Gyr: engine development AVL Budapest: engine and powertrain development Bosch Miskolc: electronic hand-tools designing Bosch Budapest: electronic developments Continental Teves Veszprm : development of electronics instruments for cars Denso Szkesfehrvr: fuel supplying system development DHS Draexlmaier rd: vehicle compartment designing EDAG Gyr: vehicle subunit development GE Lightings Budapest: car lighting Knorr-Bremse Budapest: electronic brake-system development Magna-Steyr Gyr: engineering centre Continental Temic Budapest: car electronics development Semcon Budapest: automotive design, informatics ThyssenKrupp Budapest: electronic steering development Visteon Szkesfehrvr: vehicle part and subunit development WET Pilisszentivn: electronic subunit development
Up to speed
Education in the automotive sector
Education in all areas of engineering is built on strong foundations: Hungary boasts great scientific traditions and experience in production and planning, excellent primary and secondary education (including vocational high schools with focused technical curricula), and a superb network of technical colleges and universities renowned for training highly specialised engineers. The automotive industry provides work for 110,000 people in Hungary today, of which 3,500 are university- or college-educated engineers. World-class training and education of engineers in five major cities Nearly 20 per cent of working engineers are engaged in product development, while the rest are active in technical development, production, quality assurance and sales Hungary has nearly 20,000 students in vocational education
Source: Ministry of Education
Pcs
Baja
Technical universities: Budapest Technical University, Zrnyi Mikls National Defence University Budapest, Szchenyi Istvn University Gyr, University of Miskolc, Pannonia University Veszprm, University of Debrecen, Szent Istvn University Gdl, University of Pcs, University of West Hungary, Sopron Technical institutions: Budapest Technical College, Gbor Dnes College Budapest, College of Dunajvros, Kecskemt College, Etvs Jzsef College, Baja, College of Nyregyhza
Over 53,000 Hungarians are enrolled in science courses at university level (in 2007, 17,712 in IT, 31,029 in engineering and 4,546 in manufacturing and processing).
Western Transdanubia Central Transdanubia Southern Transdanubia Central Hungary Northern Hungary Northern Great-Plain Southern Great-Plain Total
50%
3. Training subsidy
From 50% to 90% of total training costs, depending on the type of training and location of the investment
Audi Facts & figures (2007) 1.913 million engines 56,982 cars, Audi TT, Audi TTRoadster and Audi A3 Cabriolet Turnover EUR 5,870 million Workforce 5,845 people Total investments of over EUR 3,300 million Hungary's largest exporter World's third largest engine manufacturing plant
AUDI
We are confident that with our innovative technology, progressive design and exemplary environmental protection, our success will remain the same in the future. // Audi's corporate culture The management of the AUDI Hungaria Motor Ltd. is proud of the company having become one of the greatest investors in Hungary. Our output level amounts over 1.91 million engines a year, and owing to our engine development centre, machine tool factory as well as production designing and product construction we are the determining force in the Hungarian and European automobile industry. The good working culture, efficiency and flexibility of Hungarian workers have made rapid growth possible. Within 15 years, Audi in Gyr has become the world's third largest engine manufacturer and logistics had to keep pace with this expansion. // Thomas Faustmann, Managing Director, AUDI Hungria Motor Ltd.
of state subsidies
AUDI Hungaria Motor Ltd. manufactures and assembles engines, cylinder heads and cars. As a 100% affiliated company of the German corporation AUDI AG, Europe's largest facility for 4-, 6- and 8-cylinder-engines was established in 1993. AUDI is Hungary's top exporter and delivers engines to carmakers Volkswagen, Skoda and Seat. Since 1998 the company has also performed assembly work for the Audi TT and TT Roadster models. These products are manufactured according to the highest possible technical standards and are the fruits of cutting-edge development work performed all over the world. Audi Hungria Motor Ltd. is going to manufacture the 10-cylinder, 560 HP engine for the luxurious sports car Lamborghini Gallardo.
50%
SUZUKI
50%
I'm convinced that Suzuki made the right decision in choosing Hungary for its European general headquarters: the move has proved to be hugely beneficial for us, as sales figures have been demonstrating for the last 15 years. The strategic rationale for this decision was to achieve maximum synergy by combining two great assets: the reliable and economical product range designed by Japanese engineers to meet continuously evolving market demands, and the creativity, excellent problem-solving abilities and discipline of the Hungarian work force. The plan's success is evident in the unsurpassed quality of the Suzuki automobiles and auto parts manufactured here in Hungary. // Kazuhisa Toda, former General Director, Magyar Suzuki Corporation Suzuki would continue to develop safe, environmentally compatible vehicles and continue contributing to Hungary's economic development. // Hiroshi Tsuda, President and COO, Suzuki Motor Corporation
Suzuki Facts & figures (2007) 233,000 cars (Swift 3d and 5d, SX4; Ignis; Wagon R+) Planned for 2008: 300,000 units Turnover EUR 2.2 billion Workforce 6,200 people Total investment in excess of EUR 1,270 million
Magyar Suzuki Corporation has started production of the Splash world strategic model in Esztergom on 8th February, 2008. Suzuki plans to produce 60,000 units per annum. The Splash is the first model in the second phase of Suzuki's world strategy; it was designed to combine sportiness with the family-friendliness that has long been a hallmark of Suzuki vehicles, and it combines CO2 emissions of just 120 g/km with fuel consumption of just 5 L/100 km.
08 09
GENERAL MOTORS
General Motors Powertrain Hungary Ltd. was founded as a subsidiary of General Motors Powertrain Europe in Szentgotthrd in 1991. The company is the sole manufacturer of all Ecotec Family 1 gasoline engines (1.6-1.8 litre) and an exclusive producer of Allison automatic transmission for trucks and buses outside America.
A creative and flexible workforce is one of the strengths that helps General Motors Powertrain Hungary to successfully meet the challenges facing today's rapidly changing automotive industry. // Rudolf Hamp, former General Director, General Motors Powertrain Hungary Ltd.
General Motors Powertrain Facts & figures (2007) 434,617 engines 495,780 cylinder heads 19,281 Allison transmissions Workforce 667 people Total investment reached EUR 700 million by 2006
MODINE
Modine Manufacturing Company is a global leader in the design and development of heating and cooling solutions with revenues of approximately USD1.6 billion in fiscal 2007. The corporation is investing USD 12 million to build a state-of-the-art facility in Gyngys Industrial Park, further extending Modine's global manufacturing footprint. The site was chosen to leverage operating synergies with Modine's Mezkvesd site, and the decision was based on Hungary's superior local logistics and infrastructure, and favourable wage levels.
Modine wins programmes to supply approx. USD 125 million per year in EPA 2010 and Tier 4 engine cooling solutions over five years.
We are very excited to be building a second facility in North East Hungary, leveraging our manufacturing scale and creating multiple synergies to drive incremental business wins by giving us a more competitive cost position. This will enable us to continue serving the growing needs of the commercial vehicle, construction and agricultural machinery and automotive markets cost competitively. // David B. Rayburn, Modine's President and Chief Executive Officer
ROBERT BOSCH
Bosch has been present in Hungary for 109 years. The company is the second largest foreign employer in Hungary with 13 local subsidiaries and a total headcount of more than 7,000. Bosch in Hungary is increasing its efforts to adapt the domestic technical higher education system to the needs of the market by supporting numerous training programmes in Budapest, Hatvan and Miskolc. Bosch's Budapest Development Centre recruited the 300th engineer developer. The development centre recruits 100 new engineers per annum, where the highest quality of professional challenges is offered to colleagues. In 2008, a further 100 engineer developers are expected to be employed.
Bosch is continuously expanding its development activities, which is not only apparent in the growth of its workforce, but also in its increasingly varied engineering activities. Bosch is fully committed in every respect to environmental friendly and safe solutions. // Henk Becker, Director, Bosch Development Centre, Budapest
FDI stock in EUR millions in transport equipment manufacturing in Hungary by volume and as a percentage
6000 5000 4000 3000 2000 1000 0
F.SEGURA
F.Segura designs, manufactures and assembles automotive components and metal components for the biggest names in the automotive sector, such as FORD, VW, SEAT, AUDI and VOLVO. In 2007, the foundationstone for the new F.Segura Hungria Ltd. factory was laid in Szolnok. The EUR 20 million investments will be completed on 100.000 square meters in 2008 and will create 150 new jobs by the end of 2010.
ZF
In the past decade ZF's Eger site has become the development and manufacturing headquarters for the company's transmission systems for light commercial vehicles. The activities of other global ZF companies dealing with the same product group are directed from here.
Source: Central Statistical Office
1998
1999
2000
2001
2002
2003
2004
2005
12% 10% 8% 6% 4% 2% 0
2006
40 per cent of the components of transmissions manufactured by the company come from Hungarian suppliers. We also cooperate with Hungarian universities as they provide us excellent highly qualified engineers and technical professionals. // Ulrich Diller, General Director, ZF Hungria Ltd.
1998
1999
2000
2001
2002
2003
2004
2005
2006
KNORR-BREMSE
Knorr-Bremse will spend over EUR 11 million on R&D in Hungary in 2008.
This enlargement has huge significance in the history of Knorr-Bremse in Hungary, since it results in considerable increase of the number of employees, a new building and enlargement of laboratories. The R&D activity is of prime importance not only in the Group's global development organisation but also in the Hungarian technical, higher education, research and development sectors. // Istvn Lepsnyi, CEO Knorr-Bremse Ltd.
Source: UniCredit
HI-LEX
Japanese headquartered Hi-Lex is the world's largest control cable supplier with 29 operating units in 13 countries. The Hi-Lex Corporation chose Rtsg as the location for its second European production unit.
The establishment of Hi-Lex Hungary Kft. is a key milestone in the international history of the Hi-Lex Corporation and its continuing growth in Europe. Hi-Lex Hungary Kft. will play a pivotal role in the further successful growth and expansion of the international Hi-Lex Corporation in Europe. // Mike Lewis, European Director of HI-LEX Corporation/
Success by association
Automotive organisations
10 11
The Association of the Hungarian Automotive Industry (MGSZ) was founded in 1998 with the participation of ten automotive companies. Today, the Association has 27 members and represents the international interests of Hungarian producers in the Association of European Motor Vehicle Manufacturers (ACEA) and the International Organisation of Motor Vehicle Manufacturers (OICA). Association of Hungarian Vehicle Component Manufacturers (MAJOSZ) was established in 1993 by 22 founding members. It currently has more than 290 members, of which 80 are supporting members. The Association's goal is to assist its members in climbing as high up the supplier hierarchy as possible, and to help them advance from simpler to more sophisticated products, from contract manufacturing to product development projects. The Association of Hungarian Vehicle Component Manufacturers is an official member of the European Association of Automotive Suppliers (CLEPA). The Pannon Automotive Cluster (PANAC) was established in 2000 and now boasts 96 members. The organisation's mission is to facilitate national and international networking by providing opportunities for communication and partnerships, offering project sponsorship and promoting trust and willingness to cooperate among members. It also assists in company development, including surveys of supplier capacity, company benchmarking, organisation of specific automotive teaching/training programmes, and professional forums, programmes and technology exchanges.
10 1 4 7
Constanta
9
Koper, Triest
Constanta
Logistics centers Airport with public, international, commercial permanent border crossing Airport with public, international, commercial temporary border crossing Airport development opportunities Ports Railway connection Container terminal
Northern Hungary
Northern Great-Plain
Western Transdanubia Arcelor Audi Autoliv B.O.S. BPW Rba Dana Dekorsy Delphi Packard Edag EMT Erbslh Euro Exedy Euro-Elzett Eybl Federal Mogul GM Powertrain Gyri Plast Hirschler Kravtex Magna Steyr Nemak Rba Rekard Produkt Rudolph Logistik Schaeffler AG Sempeform Veritas Visiocorp Vogel und Noot
Central Transdanubia AFL Ajkai Elektronika Albert Weber Alcoa Asahi Glass Bakony Benteler Borg Warner Bourns Bridgestone Continental Teves Denso Diamond Electric Euro Exedy Gedia Gestamp Hammerstein Hankook ITW Siewer Karsai Plast Kirchoff Le Blier Lear Magyarmet Michels Musashi Plasticor Plastimat Rba SCI Sanmina SEWS Souftec Suzuki Toyo Seat U-Shin Valeo Videoton Visteon Wescast
Southern Transdanubia BHG CabTec Ratipur Central Hungary ArvinMeritor AVL Cascade Clarion Continental Catalyst Continental Temic ContiTech Draexlmaier EMT Excel Csepel FESTO GE Lighting Hokushin Ibiden Lear MGM Michelin Mono-Ipolyfabric NABI PEM Schwarzmller Siemens VDO Tauril ThyssenKrupp Toyo Seat Vogel-Sitze W.E.T. Automotive Webasto Zollner
Northern Hungary Ada-Cast Akzo-Nobel Coating ARRK Bosch Delphi-Calsonic Delta-Tech Exir Firth Rixson Ganz Foundry Gibbs Hi-Lex Knaus-Tabbert Kovcs Lear Leoni Mitsuba Modine Prec-Cast Remy Saia-Burgess Salgglas Shinwa Stanley Electric Starter Battery Technoplast ZF Hungria
Northern Great-Plain Caroflex Carrier Transicold Eagle Ottawa Eismann EMCON Technologies/ ArvinMeritor Euroszol F.Segura Hajdu Aut Hbner Isringhausen Le Blier Michelin Nief Phoenix Schaeffler AG Southern Great-Plain Continental Phoenix Csaba Metal Eckerle Emika Hirschmann Kaloplasztik Knorr-Bremse Kunplast Linamar ThyssenKrupp
Project preparation
In-depth, tailored information on the local economy and business climate, corporate taxation and the legal environment, as well as sector specific overviews Site visits, meetings with local, regional and government bodies and introductions to local suppliers, service providers and experts Information on available incentives
Implementation
Site selection assistance, coordination of licensing procedures Finalisation of incentives agreements Assistance with recruitment and visa application VIP treatment for expatriate employees
After care
Intermediary role for future developments between government bodies and foreign companies operating in Hungary Support and generation of reinvestments Through a diverse set of marketing tools and support programmes, ITD Hungary offers substantial logistical, financial and professional assistance to both start-up and established Hungarian exporters. A large proportion of the Agency's trade promotion activities are carried out by its Customer Relations Centre, operating under the Business Development Directorate. ITD Hungary also co-ordinates the Hungarian activities of the Enterprise Europe Network, supported by the European Commission. The network offers support and advice to businesses across Europe and helps them make the most of opportunities in the European Union. ITD Hungary develops and distributes printed and electronic business guides, trade directories and information booklets in a variety of languages. The Agency arranges business programmes for individual visitors and delegations, organises conferences, exhibitions, product showcases and other business events.