Springs
Dedicated line for complex assemblies: +35% productivity
As production volumes increase, even small amounts of time lost to setup, maintenance, or equipment downtime can quickly add up, significantly impacting overall production line efficiency. The challenge becomes even greater when manufacturing complex assemblies, where multiple components and operations must be coordinated while meeting stringent quality and traceability requirements.
This was the challenge Mollificio Bergamasco addressed for a major customer in the electromechanical sector: industrializing the production of assemblies consisting of screws, resistance-welded contacts, and terminals while overcoming the limitations of the existing manufacturing process.
The solution was a dedicated, modular production line engineered for high-volume manufacturing. By reducing setup times and equipment downtime while improving process reliability, the new line increased productivity by 35%.
Reducing setup times and downtime in complex assembly manufacturing
The project was driven by the need to improve the efficiency and reliability of a manufacturing process affected by several critical issues: lengthy setup and maintenance operations, limited production flexibility, and frequent equipment downtime.
Particularly in high-volume manufacturing, companies must balance high output with increasingly stringent quality and traceability requirements. The objective was therefore to optimize the entire manufacturing process to achieve greater stability, control, and efficiency.
The solution: a production line developed according to APQP principles
Mollificio Bergamasco engineered a dedicated, modular production system, focusing on production tooling, process flow, quality control, and equipment maintenance.
APQP (Advanced Product Quality Planning) principles guided the design of the production system, while the production tooling followed the “Lean MBG” methodology. Process flows were also optimized and standardized to minimize inefficiencies and process variability.
Automated in-line inspection is another key element of this solution. Dedicated sensors and 100% inspection enable the system to detect process faults and non-conforming parts, helping ensure consistent product quality throughout production.
To further improve equipment reliability, Mollificio Bergamasco introduced a predictive maintenance system that integrates with the MES. Continuous condition monitoring makes it possible to anticipate servicing needs, reducing unplanned downtime, and minimizing the impact of scheduled interventions on production availability.
The results: +35% productivity and 40% lower setup costs
The new production line delivered measurable improvements across key manufacturing performance indicators:
- 30% reduction in SOP lead time
- 40% reduction in setup and routine maintenance costs
- 35% increase in productivity
- 40% reduction in maintenance costs through predictive maintenance
- stable, high-quality output with a significant reduction in defect PPM
This project demonstrates how the industrialization of complex assemblies can be successfully addressed through a coordinated approach that combines production line engineering, automation, in-line quality control, process standardization, and predictive maintenance.
Mollificio Bergamasco designs and manufactures springs, stamped and formed metal components, electrical contacts, and assemblies. The company supports customers throughout product and manufacturing process development, from co-design and prototyping through validation and series production. By investing in automation, in-line inspection systems, and advanced manufacturing technologies, Mollificio Bergamasco ensures high levels of component precision, process repeatability, and consistent product quality.
