Bianchi APS

Company name

Bianchi Spa

project title

APS Bianchi Project

dimension and location

Large Enterprise – Treviglio (MI)

Partner

Siemens

technologies

Lean Manufacturing 4.0
Smart monitoring and control of industrial processes

Bianchi, an iconic Italian brand and global leader in the bicycle industry, continues to stand out for its quality and innovation, upholding a tradition of over 135 years of excellence. Among the many awards it has received, international recognition for the design and engineering of its products stands out.

The problem

Bianchi aimed to bring part of its production activities back to Italy by opening a new facility in Treviglio with much greater production capacity. The return of production to Italy required a complete redesign of business processes to efficiently manage the increasing operational complexity. The previous planning process for production and procurement was manual, with little support from automated systems, relying on spreadsheets and reports from the ERP system, resulting in a highly time-consuming and resource-intensive process.
To address this challenge, Bianchi collaborated with MADE Competence Center Industria 4.0 on an ambitious digital transformation project based on the implementation of the Advanced Planning System (APS), an advanced production planning and scheduling system by Siemens, a partner of MADE4.0.

The solution

Technologies:

The implementation of an APS system eliminated the previous manual management, speeding up the creation of procurement and production plans and ensuring optimal assembly sequencing within the factory. This improved response times between various business functions, from sales to procurement, and made internal logistics more efficient.

Desired Impacts

  • Production Optimization: The adoption of APS enabled Bianchi to improve resource management and production cycles, reducing waste and downtime. With more precise and dynamic planning, the company can quickly adapt to fluctuations in demand, ensuring timely deliveries and greater production efficiency.
  • Managing Operational Complexity: The increased production capacity at the new facility required a system that could effectively coordinate departments and production lines. APS provides a unified view of planning, facilitating coordination between different production stages and improving resource utilization.
  • Flexibility and Customization: APS allows Bianchi to better respond to the growing demand for customized products, a rising segment in the high-end bicycle market. The system enables the rapid adaptation of production lines to meet specific customer needs, increasing competitiveness.
  • Sustainable Production: APS technology helps to reduce environmental impact by optimizing resource use and minimizing downtime. This allows Bianchi to pursue sustainability goals, promoting more eco-friendly production.
  • Health and Safety: Thanks to APS, Bianchi optimized resource allocation, enabling targeted management of personnel based on specific skills and certifications. This advanced approach ensures efficient human resource distribution, improving workflow and maximizing productivity.

Benefits for the company

Among the main benefits for Bianchi Spa is the implementation of effective production planning, capable of managing both medium to long-term needs, ensuring timely availability of raw materials, and short-term needs, by monitoring the actual presence of materials in the facility. One of the strategic priorities was optimizing the procurement process through flexible management of supply times to ensure a constant flow of resources. At the same time, Bianchi focused on improving delivery date planning for customers, optimizing warehouse management and workforce utilization.

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