Plants

New technologies and efficient production processes: our Industry 4.0 challenge starts here, without ever losing sight of safety and protection of the environment.

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“The new factory, equipped with cutting-edge technologies, will contribute to improving the company’s ability to provide transmissions for Indian customers according to the highest production standards.”

Raghu Ananth
Manufacturing Engineer, Comer Industries India, Bangalore, India

Comer Industries India

Opening

June 2016

Covered surface area

4,500 sq.m.

Applications

Self-loading concrete mixers
Front loaders
Asphalt pavers
Asphalt compactors
Telehandlers
Special vehicles

2016 turnover

4 million euros

2017 turnover

10 million euros (estimate)

Employees 2016

40

Plant strategy

Local for local

“Thanks to the “Virtual Validation” we can predict the behavior of the complete gearbox in terms of stress and duration, taking into account the mutual interactions between the single component parts.”

Elisabetta Fava
Engineer, Headquarters, Reggiolo, Italy
NEW EQUIPMENT AND MACHINING CENTERS

We invest in technological innovation

Completion

Completion of activities on 2 new machining centers dedicated to gearboxes and planetary gear carriers in Comer Industries Components of Matera.

Renovation

Renovation of cast-iron working machines in the Reggiolo Gearboxes facility.

Verticalization

Technological choices to complete gear machining flow in the new Reggiolo “one-machine plant” through the verticalization of heat treatment and the renovation of the gear cutting machines.

Industry 4.0 represents a unique chance to grow professionally. Introducing new technologies into the company will enable us to continue to have a competitive edge at the international level."

Riccardo Pignatti
Corporate Manufacturing Engineer, Headquarters, Reggiolo, Italy
APPLICATION OF WCM IN THE PLANTS

Comer Industries is the number one supplier of CNH Industrial in the world

In the fourth World Class Manufacturing (WCM) audit, Comer Industries achieved a score of 45. This makes it the first supplier of CNH Industrial in the world to have scored over 40 in the evaluation of the correct application of WCM in its plants. The method enables us to standardize work, reduce waste and increase the involvement of our employees with a view to continuous improvement. Quality, safety, on-time delivery and cost cutting performances are also on the upgrade.

KAIZEN WORKSHOPS

130 projects for continuous improvement

In 2016 we set up 130 Kaizen workshops to improve processes and products thanks to the creation of value and the elimination of waste. This year we have mainly focused on the goal of limiting costs, as well as on quality, safety, the environment and the punctuality of deliveries.

ENERGY SAVING

New technologies to be increasingly more sustainable

Compressor inventory with inverter technology in the Reggiolo plant

Latest-generation high-frequency energy storage and release systems

Low energy impact heat and cold generation systems

Extension of energy consumption monitoring systems

Extension of production plant production standby control systems

ISO 50001 energy-management certification in the Matera plant

TOTAL COST OF OWNERSHIP

The transparency of the Supply Chain

The application of Total Cost of Ownership (TCO) allows us to identify the direct and indirect costs of a product during its entire life-cycle. In this way we can correctly locate supplies, avoiding hidden costs caused by errors, thereby containing the overall cost of acquisition.
Combined with the Open Book approach of sharing of information in real time, TCO is a useful tool for guaranteeing transparency in the supply chain and for increasing company competitiveness.

SAFETY TRAINING AND INITIATIVES

Towards a prevention-based culture

Enhanced awareness: this is the key for improving safety and reducing risks.
We have set up training courses and the monitoring of dangerous behaviors and of accidents in all plants.
To foster a prevention-oriented culture, we have promoted projects for the signaling of any risky behavior and critical situations on the part of the staff in production departments and, afterwards, the monthly monitoring of problem-solving actions to eliminate them.

PROBLEM SOLVING, COURSES AND PPAP

Quality performances are improving

Improvement activities regarding internal production processes and the growth of the supply chain have led to increasing the quality of performances.
The training, problem-solving and analysis of approval phases for new products through the PPAP have proved to be of strategic importance. The Production Part Approval Process allows us to establish whether all the requirements of the project and of the product have been met and if the supplier’s production process is able to maintain compliance in a series production.