e Successfully – The GYS Way


engineers worked collaboratively on all aspects of the range of GYS products. Benches had prototypes, in-production machines and components on them, while computer systems were used to monitor performance and results. Many of the engineers were “local lads” employed by GYS soon after leaving school and given many opportunities to develop their skills within the company as well as being able to “go for promotion”. The efforts of the R and D engineers were translated into real products on the


factory floor by the 200 production staff. Again I was struck by the unhurried pace of production where individuals take responsibility for a series of tasks. GYS tries to encourage flexible working practices where people are trained to do as wide a range of tasks as possible. This means that people can be moved to where they are needed most with the confidence that they will be able to do the job they are assigned to, to the highest quality standards. In 1997 GYS made the decision to have an integrated manufacturing system as


a cornerstone business philosophy. This means that GYS produces all the metal and electronic components in-house. In this way they have absolute control over quality and fitness for purpose. GYS also has a rigorous testing regime at component level, thus avoiding the problem of machines being built with faulty bought-in components. I was actually amazed that within a relatively compact manufacturing space


there were computer-controlled machines that punched metal sheet body parts, made mechanical components, painted and labeled the body parts, made cabling, connectors and wound transformers. The humans supervised the machines, checked quality controls and collected the completed parts to take them to the manufacturing stations. It seems as though the only components that GYS don’t make for themselves


are plastic parts. Bruno was also keen to stress that GYS is a company that listens to its


customers. Managers and field staff regularly confer with buyers and users who make suggestions about what GYs could make to suit their particular needs. As a result of this consultation process, three new machines particular to the UK market have already been introduced. Indeed, while I was visiting the factory, senior engineers from a major French


car makers were at GYS to consult on the range of GYS motor body repair welding rigs. Increasingly complicated car body designs and the need for repairs that meet insurance standards require machines that can do a range of tasks and record the repairs too. GYS has a few of these if you need one! Looking at the numbers, GYS is in an enviable position. Turnover has been steadily rising year-on-year from 7 million Euros in 1997 to an estimated 60 million


Euros in 2012. Most of GYS’ machines are exported to Europe, but with growing percentages going to Asia, Africa and Australasia. GYS now has sales subsidiaries in Germany and the UK, and a manufacturing


facility in Shanghai making low technology and non-professional products. The product range is also expanding. An increasing number of models of


welding rigs make up 65% of the GYS range. Car body repair is currently a strong focus with 20% of the range, while the rest is made up of a range of increasingly high tech battery chargers, from hobby to professional. After seeing all this welding and charging technology being made, my fingers


were twitching. In a surprise move by Bruno, I was whisked up to the spacious product training area and let loose on a few welders. I was given the opportunity to try out MMA/ Stick , MIG and TIG welders under the guidance of one of GYS’ trained demonstrators. I was very impressed with the GYS range of welders as they make full use of


advances in electronics and software to improve the welding process by removing some of the guesswork. For example, high-tech software prevents the electrode sticking and initiating an initial welding arc is made much easier by “hot-start” technology. There are some that may argue that this is a “de-skilling” of welding, but in fact it is much more like an enabling process, since welding technology is opened up to a much wider range of people and their specific welding needs. Even in MIG welding, which is regarded as a very highly developed skill, the


GYS SMARTmig entry level welder has a control panel enabling the user to set wire speed and power to the correct levels without costly trial and error methods. We don’t miss typewriters compared to word processors, nor cathode ray TVs


compared to LCD TVs, so it seems only sensible to decide in favour of “smart” welders too. GYS are very proud of the fact that their range of welders and other products


covers a full spectrum from occasional users to professionals with all price points covered. What became clear to me as I toured the factory was that each and every product no matter how simple or complex, was rigorously tested – one of the pluses of the integrated manufacturing philosophy. Each GYS machine will be tested comprehensively after manufacture to ensure that it starts its working life properly. Other more sensitive parts like PCBs are actually tested twice before assembly and then as part of the whole machine. Users may only pay around £120 for a basic GYS welder, but can rest assured


that it has had the same quality control as GYS machines costing a great deal more. And perhaps that brings me round in a circle to the point where I started – the


fact that GYS is a manufacturing success story is not an accident. Excellent products will always find a market, particularly if they come at the right price.


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