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We employ state-of-the-art technology at our modern facilities in Pregrada, Poznanovec and Bačko Gradište – globally known Dürkopp Adler and Pegasus sewing machines and Lectra cutters.
The manufacturing is fully adjusted to best meet our customers’ needs, which means that we take an active part in quality planning and control, as well as in feasibility checks of newly manufactured product components and their alterations in compliance with the APQP procedures.
Our daily output ranges between 18.000 and 20.000 units. However, the automotive industry often requires swift response to emergencies, which is why we can increase our production capacity for new product lines at any given moment.
Despite employing state-of-the-art technology, we believe that a machine can never override the need for a skillful, powerful and precise human hand. With skillful and diligent hands of more than 500 sewists, we produce seating systems unmatchable in quality, precision and accuracy. Our strength lies in the strength of their hands.
Prior process and product testing of newly designed components is an important step before any batch production. The manufacturing is subject to approval and final confirmation provided by the client to avoid any potential misunderstandings (PPAP).
We adhere to the Failure Modes and Effects Analysis (FMEA) procedure, which involves a diverse team of experts and allows us to maintain the quality standards at every level.
All technical materials are registered in the International Material Data System (IMDS) and adequately labelled in accordance with the industry regulations and requirements.
Production execution is monitored by the QAD/MFG system, while the EDI system facilitates the communication process with customers. We have also introduced the Measurement System Analysis (MSA) with 0.5 mm tolerance that guarantees high precision craftsmanship and exceptional final product quality.
For us batch production, unmatchable quality means that we strive to have zero repairs and minimum material waste. That is why we constantly improve production quality and make regular investments in service enhancement to reduce the error rate.
The implementation of ISO/TS 16949 quality control system allows us to promote continuous improvement, fault prevention and the structured quality planning approach to product design. We comply with the AIAG’s APQP, PPAP, MSA, FMEA and SPC procedures.
We take an active part in the new product development process and perform preventive actions such as production analysis, error probability, reliability calculations, etc. Any findings are taken into account before starting batch production. We draft detailed action plans for all our projects.
Our entire production is focused on continuous improvement and betterment, and scrupulous attention is paid to error aversion and finding cost cutting solutions.
The change in automotive industry is unstoppable. We, who take part in this industry, strive to make our own contribution to nature conservation and healthier environment via energy efficiency projects, the use of renewable energy sources and good daily business practices.
In 2023 we completed an important project “Increasing energy efficiency and the use of renewable energy sources in manufacturing industries” funded by the EU.
The above-mentioned project included energy retrofitting of our production and office premises in Pregrada, i.e. installation of LED light bulbs, procurement of energy efficient sewing machines, installation of heat pumps as well as the solar PV power plant for electricity generation.
The foregoing project helped us to reduce the consumption of electricity delivered from the distribution grid by as much as 50% and to make a great step forward towards sustainable production.
KOSTELAR d.o.o.
Ulica Josipa Štruka 3
49218 Pregrada, Croatia
