Case History

The Challenge
A major customer in the electromechanical sector needed to industrialize complex assemblies consisting of screws, resistance-welded contacts, and terminals.
Main critical issues included excessive set-up and maintenance times, limited flexibility, frequent downtime, and increasing requirements for quality and traceability.
The Solution
Mollificio Bergamasco developed a dedicated, modular production line optimized for high volumes.
Key actions:

1. Production system design with an APQP approach
2. Tooling design based on the “Lean MBG” philosophy
3. High fault and defect detection capability through sensors and 100% automatic controls
4. Process flow optimization and standardization
5. Implementation of a predictive maintenance system integrated with MES to increase equipment reliability

Results

1. –30% SOP time
2. –40% set-up and routine maintenance costs
3. +35% productivity
4. –40% maintenance costs through predictive maintenance
5. Stable, high-quality output with significant PPM reduction

Mollificio Bergamasco confirms its role as a reliable partner for high-precision assemblies and advanced production line design.