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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 take place during the first half of 2011 concerning these sites, aimed at developing and streamlining production capacity, are outlined below.

Pontedera Sites

Two-Wheeler and Engine production sites

As part of mechanical processing, industrial-scale production of the following new components for relative engines was completed: Integral Drive Shaft (Motoguzzi 1400 California engine), Crankcase, Drive Shaft, Hub Assembly, Cam Axles (350 engine), Drive Shaft, Cam Axles (850cc engine for John Deere). Industrial-scale production of crankcase components and gears for the LEM engine, and the hub assembly for the Liberty Electric engine are underway.

Units for processing 350cc engine crankcases were started up, and the ICOM washing plant (aluminium crankcase) was reconditioned.

As concerns engine assembly, installations for new assembly lines for the 350cc engine and 850cc engine for the customer John were completed. The industrial-scale production of equipment for assembly of the Liberty Electric engine is underway. A new production line is being developed for assembly of the LEm engine, scheduled for start up in the first half of 2012. Wireless coverage of the Engines Site was completed.

As regards vehicle welding, the continuous wire welding unit for ZIP and Stalker vehicles and the MP3 steering tube was renovated, while in terms of vehicle painting, actions were defined in technical terms for the inclusion of the new SIP (Product Routing System). The SIP should be installed in the second half of 2011 and is scheduled for start up in the first half of 2012.

As concerns two-wheeler vehicle assembly, processes for assembly of the MP3 YOURBAN, and Vespa PX were given the go ahead. A new pallet automatic transfer line has been installed to assemble MP3 suspension.

Commercial Vehicles Plants

As regards painting, activities to install and optimise programmes on 2 new ABB robots fitted with electrostatic torques on the VRN Ape line, were completed.

Scorzè Plant

Activities for the industrial-scale production of the RS4 50/125 and Tuono 1000 v4 were completed.

The project to requalify the scooter production building was completed, with the disposal and complete replacement of old asbestos cement slabs.

Mandello del Lario Plant

The construction of the new porter's lodge is being completed and is expected to open in the second half of 2011 and demolition of former mechanical processing buildings and the warehouse area was completed.

A new motorcycles packaging line was installed and has been operating since April 2011.

The certification and conformity of equipment for engine and vehicle assembly was also completed.

Baramati Plant

Work continued in the first half of 2011 to build the new two-wheeler plant in India and for the installations needed to manufacture the new HE engine.

Hanoi Plant

The second vehicle assembly line went into operation. Mass production of the Vespa Lx/S, Liberty 125/150cc, and ZIP began.

The industrial site is being expanded, with the construction of new industrial buildings for mechanical processing and for engine and spare parts assembly. The work started in the first half of 2011 and is expected to be completed in the first six months of 2012.

World Class Manufacturing Project

The Piaggio Production System (PPS) is wholeheartedly committed to improving the production system of all Italian plants, based on three factors: work methodologies, tools to analyse processes and human resources. Its actions so far have concerned improvement planning.

30 comparative audits have been conducted for methodologies and knowledge already in use, creating 26 Good Practices to be extended from the best site to all other sites, as well as 31 improvement projects.

As concerns methodologies and knowledge to develop, the first part of training for Plant Managers was performed.