{"id":16591,"date":"2018-12-05T00:00:00","date_gmt":"2018-12-04T23:00:00","guid":{"rendered":"https:\/\/sapastaging.com\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve\/"},"modified":"2024-10-01T10:10:59","modified_gmt":"2024-10-01T09:10:59","slug":"when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve","status":"publish","type":"post","link":"https:\/\/sapastaging.com\/it\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve\/","title":{"rendered":"WHEN WE USED TO THINK THAT PRODUCING 1,000 C LOWER PILLARS PER DAY WAS AN IMPOSSIBLE GOAL TO ACHIEVE"},"content":{"rendered":"<h2><span style=\"color: #ff0000;\">Thanks to the One-Shot\u00ae Method &#8211; the innovative method that is revolutionising the automotive sector, the upholstering process of the c lower pillar is now completely automated. and productivity increased to 110%.<\/span><\/h2>\n<p>Today I want to talk to you about one of our most innovative products. I\u2019m referring to the C Lower Pillar, already industrialised on the Alfa Romeo Stelvio.<\/p>\n<p>I\u2019ve been thinking long and hard how to best describe to you the changes that the innovation of this part has brought about.<\/p>\n<p>To convey this, <strong>I have decided to start from the beginning, <\/strong>from something that <strong>pertains to you, me and anybody who looks to the future<\/strong> and who wants to innovate in order to improve their way of working. I am talking about the rise and evolution of the car as a means of transport and as a private possession.<\/p>\n<p>Let me try to explain what I mean.<\/p>\n<p>I start from one premise: <strong>mankind has always sought speed. <\/strong>The reasons for this are manifold: overcoming limitations, reaching the destination in shorter time, saving time etc\u2026. Thinking about it, all these reasons pertain to the work we do.<\/p>\n<p>Not only cars, but all the means of transport have developed along these lines to achieve these objectives.<\/p>\n<p>Yet, if we look really closely, <strong>nothing was as much of an innovative breakthrough in terms of freedom and independence and nothing hit the mark as much as the car did. <\/strong>Especially if we compare it with going on foot.<\/p>\n<p>These are namely the features that make the car into the synonym of freedom and efficiency:<\/p>\n<ul>\n<li><strong>Speed: <\/strong>the car is the evolution of walking and makes you save time. If you go the same way, by car you\u2019ll get there faster.<\/li>\n<li><strong>The need to reach an exact destination:<\/strong> trains and planes are incomplete from this point of view, because they always necessarily require an extra means of transport.<\/li>\n<li><strong>The ability to organise the journey quickly:<\/strong> if you go by car, you don\u2019t need to plan in advance.<\/li>\n<li><strong>Comfort:<\/strong> the car offers comforts that are designed and produced especially for the client, hence the car is a personal and customisable product.<\/li>\n<\/ul>\n<p>You see, this evolution that I have just explained has a lot in common with the car part that I\u2019d like to talk to you about.<\/p>\n<p>The <strong>One-Shot\u00ae C Lower Pillar <\/strong>differs from any other C Lower Pillar because <strong>its production process was completely automated by SAPA, <\/strong>which entails sizeable advantages.<\/p>\n<p><a href=\"https:\/\/staging-222413.xyz\/wp-content\/uploads\/2018\/12\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve_01.jpg\"><img fetchpriority=\"high\" decoding=\"async\" class=\"aligncenter size-large wp-image-10301\" src=\"https:\/\/staging-222413.xyz\/wp-content\/uploads\/2018\/12\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve_01-1024x683.jpg\" alt=\"\" width=\"1024\" height=\"683\" \/><\/a><\/p>\n<p>It\u2019s as if SAPA\u2019s One-Shot\u00ae C Lower Pillar was the car and the other processes were the pedestrians.<\/p>\n<p>When we decided to innovate our C Lower Pillar through the One-Shot\u00ae Method, we focussed on how it was being produced traditionally and for each production phase we analysed the issues.<\/p>\n<p>The manual upholstering work flow is namely made up of many phases \u2013 I\u2019m sure you know them well.<\/p>\n<p>The traditional process is still <strong>carried out manually by a skilled worker, <\/strong>and this comes with risks of unforeseen issues, which are certainly counterproductive for your work.<\/p>\n<p>In particular, the traditional production method is characterised by:<\/p>\n<ol>\n<li><strong>Long production times: <\/strong>because a foaming process is foreseen, the traditional C Lower Pillar production requires specialised workers, with a 40-minute production time per piece.<\/li>\n<li><strong>Manual production: <\/strong>since the base is produced by hand, there\u2019s a higher risk of errors and especially, there\u2019s more waste.<\/li>\n<li><strong>High cost: <\/strong>producing by hand requires having a lot of workers, hence more quality assurance personnel and more training. In this way, traditional C-Lower Pillars production costs are 40% higher than with the One-Shot\u00ae method.<\/li>\n<\/ol>\n<p>We tried to sum up the problem:<\/p>\n<p style=\"text-align: center;\"><em>We needed to find a way to upholster the PVC piece of the C Lower Pillar with leather and fabric at the same time.<\/em><\/p>\n<p><a href=\"https:\/\/staging-222413.xyz\/wp-content\/uploads\/2018\/12\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve_02.jpg\"><img decoding=\"async\" class=\"aligncenter size-large wp-image-10302\" src=\"https:\/\/staging-222413.xyz\/wp-content\/uploads\/2018\/12\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve_02-1024x683.jpg\" alt=\"\" width=\"1024\" height=\"683\" \/><\/a><\/p>\n<p>So, at SAPA we decided to create two moulds, one for the plastic and one for the foaming, <strong>and to join the two processes in one single automated step.<\/strong><\/p>\n<p>I guess you\u2019re wondering how this is possible? Let me explain.<\/p>\n<p>The One-Shot\u00ae Method is a work process that aims at optimising the production phases and in most cases allows us to produce a part in just one step.<\/p>\n<p>This very clearly brings several advantages, like:<\/p>\n<ul>\n<li>Reduction of the parts\u2019 weight<\/li>\n<li>Better cost efficiency<\/li>\n<li>High quality performances<\/li>\n<\/ul>\n<p>In the case of the C Lower Pillar, after joining and positioning the two pieces together with the fabric, the leather and PVC onto a machine, a robot controls the position of the sewing, it applies the glue and welds everything automatically.<\/p>\n<p><strong>All this takes place in 80 seconds.<\/strong><\/p>\n<p><a href=\"https:\/\/staging-222413.xyz\/wp-content\/uploads\/2018\/12\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve_03.jpg\"><img decoding=\"async\" class=\"aligncenter size-large wp-image-10303\" src=\"https:\/\/staging-222413.xyz\/wp-content\/uploads\/2018\/12\/when-we-used-to-think-that-producing-1000-c-lower-pillars-per-day-was-an-impossible-goal-to-achieve_03-1024x683.jpg\" alt=\"\" width=\"1024\" height=\"683\" \/><\/a><\/p>\n<p>With the following results:<\/p>\n<ul>\n<li><strong>Better quality and a robust, standardised and GUARANTEED process: <\/strong>the machine process is 100% certified while a process based on a human operator yields lower quality and has a higher risk of differences among the pieces.<\/li>\n<\/ul>\n<p><strong>This means that you will no longer have to worry about imperfections and you can save on the cost of specialised workers. <\/strong><\/p>\n<ul>\n<li><strong>High production capability and high production volumes: <\/strong>Producing 1,000 C-Lower Pillars per day means fulfilling a demand for 500 sets per day, or 120,000 cars per year.<\/li>\n<\/ul>\n<p><strong>This means that you will improve the quantitative performance of your business.<\/strong><\/p>\n<ul>\n<li>Process and technology applied <strong>for the first time to big pieces <\/strong>like the C-Lower Pillar<\/li>\n<\/ul>\n<p><strong>This is an innovative investment in technology for you and your car maker.<\/strong><\/p>\n<ul>\n<li><strong>Less costs: <\/strong>if you draw a business case and you analyse manual production vs automated production \u2013 even in the case of equal cost of manpower, automated production costs less.<\/li>\n<\/ul>\n<p><strong>That is to say: you can invest in other parts that you have issues with.<\/strong><\/p>\n<p>We are talking about increasing productivity to 110%. You\u2019ve read correctly: 110%.<\/p>\n<p>In short, at SAPA we were able to attain the production of 1,000 C Lower Pillars per day thanks to this method, with a cycle time of 80 seconds.<\/p>\n<p>It looks like a revolution and I can assure you that it is.<\/p>\n<p>Just like the car was a revolution.<\/p>\n<p>&nbsp;<\/p>\n<p>Kind regards,<\/p>\n<p><em>Giovanni Affinita,<\/em><\/p>\n<p><em>Executive Director and Member of the Board of Directors at SAPA<\/em><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"text-align: center;\"><span style=\"color: #ff0000;\">If you\u2019d like to find out more on SAPA\u2019s patent for the one-shot\u00ae C lower pillar or use this technology immediately to optimise production times and increase productivity, fill in the form below. <\/span><\/h2>\n<h2 style=\"text-align: center;\"><span style=\"color: #ff0000;\">we\u2019ll get back to you within 24 hours!<\/span><\/h2>\n<p><strong>\u00a0<\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Thanks to the One-Shot\u00ae Method &#8211; the innovative method that is revolutionising the automotive sector, the upholstering process of the [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":16592,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-gradient":""}},"footnotes":""},"categories":[14],"tags":[238,299,239,351,396,390,249],"_links":{"self":[{"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/posts\/16591"}],"collection":[{"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/comments?post=16591"}],"version-history":[{"count":1,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/posts\/16591\/revisions"}],"predecessor-version":[{"id":17760,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/posts\/16591\/revisions\/17760"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/media\/16592"}],"wp:attachment":[{"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/media?parent=16591"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/categories?post=16591"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/sapastaging.com\/it\/wp-json\/wp\/v2\/tags?post=16591"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}