Piaggio and its production sites
The Piaggio Group has a strong international presence.
At its Italian headquarters in Pontedera (in the province of Pisa), the Group has set up the most important industrial complex in the European two-wheeler sector, in addition to a further two sites in Italy (at Scorzè and Mandello del Lario) and one in Spain (at Martorelles) for the manufacture of vehicles for the European market.
The Group also has its own production sites in India (at Baramati, in the state of Maharashtra) for the manufacture of commercial vehicles, and in Vietnam (at Vinh Phuc), with a site which went into production in June 2009 and manufactures two-wheeler vehicles.
The main operations taking place during 2010 concerning these sites, which aimed to develop and make production capacity more efficient, are outlined below.
Pontedera Sites
Two-wheeler sites
As part of mechanical processing activities, industrial production of new integral drive shafts for the new product range (Dorsoduro 1,200cc, 1,200cc 2V Motoguzzi, 1,000cc Aprilia Tuono) was completed, and the purchase of a new ion induction furnace for drive shafts and cam axles was finalised. The furnace will start up in the first half of 2011. Units for the processing of 350cc engine guards were set up and relative work centres were fully revised.
As part of engine assembly processes, equipment for the 1,200cc Dorsoduro engine and Vespa PX 1,200cc engine was completed, while installations for new assembly lines for 350cc and 850cc engines, to go into production in the first half of 2011, are being finalised.
Internal re-layouts for Vespa welding lines were completed, with 2 new automatic spot welding units going into operation.
Commercial Vehicles Plants
A project to replace worn robots with a new robot unit with equipped benches for welding decks for the APE TM and APE 50 and inner sill panel for the APE 50 was completed, as well as a project to replace robots in the painting department.
Equipment was also developed for the manufacture of Porter vehicles with new MultiTech 1,300cc petrol engines and BTC 1,200cc engines, which will go into production in the first half of 2011.
Scorzè Plant
A project to renovate the scooter factory roofing got underway, with works scheduled for completion in the first half of 2011.
Mandello del Lario Plant
Renovation works for the second stage of the Arrocco project were completed. Demolition works were finished and construction of the new company porter’s lodge began.
The construction of a new packaging line for motorcycles commenced and will go into production in the first half of 2011.
Baramati Plant
During 2010, a new line for manufacturing engines went into production as of the Indian site. Equipment was also installed for the manufacture of the new HE engine, with mass production starting in 2011, and for mechanical processing and assembly and testing processes.
Projects for the construction of a new welding, painting and assembly plant for the Vespa India got underway.
Vinh Phuc Plant
A second scooter production line was installed and the process for assembly of the Liberty got underway, which is scheduled for mass production in the first few months of 2011.
Expansion of the Vietnamese industrial site also began, with the design of new industrial warehouses for mechanical processing and engine and spare parts assembly. Works are scheduled for the first half of 2011.
World Class Manufacturing Project
The second stage of the World Class Manufacturing (WCM) project began. After an initial and essential preliminary stage based on lean manufacturing methodologies, a more clear-cut World Class Manufacturing approach was adopted.
The Piaggio Productions System (PPS) was defined, which is the operating standard for all Group production sites. The PPS is the focus of a comprehensive innovation programme for continual improvement targeting all types of waste. KPI systems to measure improvement and audits to assist management in disseminating the PPS were defined. A training programme got underway for staff, focussing on methodologies and tools, the proper application of which is essential for improving the PPS.
Environmental, Quality and Occupational Safety certification
After Piaggio Vietnam was awarded ISO 9001:2008 certification in October 2009, the new engine plant of Piaggio Vehicles Private Limited obtained certification for its quality management system in August 2010.
In December 2010, certification to UNI EN ISO14001:2004 (environmental management system), UNI EN ISO 9001:2008 (quality management system) and BS OHSAS 18001:2007 (occupational health and safety management system) was renewed for the December 2010 / December 2013 period for the Pontedera, Noale and Scorzè sites. The Mandello del Lario site obtained the above certification for the first time.
The Spanish plant as of Martorelles also obtained ISO 9001:2008 certification in December 2010.
On 25 January 2011, the environmental management system of the Vinh Phuc site in Vietnam was certified to ISO 14001:2004.
