The company spreads over a total area of 25 hectares, of which 7 hectares of covered surface, and employs approximately 700 people.
Inside the plant, AGCO Production System is applied based on the theory of lean manufacturing.
The core idea of lean production is to focus relentlessly on eliminating all aspects of the manufacturing process that add no value from the customer’s perspective, in order to improve efficiency, effectiveness and profitability.
1 COMBINE ASSEMBLY LINE
At the height of production, 7 combines a day will leave the Assembly Line during a 9-hour shift.
Groups and subgroups of the whole range of combines produced in Breganze are assembled in the different pre-assembly areas alongside the main line.
2 SETTING & TESTING TUNNEL
At the end of the assembly line the machine is transferred into the Setting & Testing Tunnel.
Here, a dedicated team checks 100 inspections points according to specific check lists based on pre-delivery inspections and on customers’ reports. The combine harvester is subject to static, low, and full speed dynamic tests. Tests can last up to 8 hours, depending on the model.
To guarantee our customers a top level quality, we ensure continuous training to our staff and carefully check every phase of production.
A new supermarket has been organized with horizontal development of the shelves to enable a new, easier and faster picking method.
This massive re-layout is part of a great improvement plan aiming to a new material flow to enable a more rational and efficient production process.
4 CUTTING HEADER ASSEMBLY LINE
Three different types of cutting headers, in various dimensions from 4.20 m to 10.74 m, are manufactured on this production line: the L-series, the Free Flow and the Power Flow headers.
5 AGCO PARTS
AGCO Parts - Breganze Division – receives, stores and distributes genuine parts to support AGCO brands dedicated to harvesting machines/machinery and tractors.
It provides original spare parts directly to Dealers throughout Italy, and indirectly to the other countries in Europe, Africa and Middle East through its network of warehouses in the UK, France, Spain, Finland, Turkey and Sweden.
This department is dedicated to the continuous development and testing of new technological products to accomplish AGCO vision: providing high-tech solutions for professional farmers feeding the world.
7 PAINT SHOP
The new paint shop covers a surface of 6,000 square metres and consists of two paint systems: Electrophoretic Coating (e-coat) and Powder Coating.
Parts are loaded on automated transfer cranes, in different areas according to their size, and subject to the cataphoretic coating process. This grants a better corrosion protection to the piece and is the base for all the parts especially the internal parts.
After the e-coating process, the parts are cured and dried in an oven between 170-190°C, depending on their thickness. Moreover, all of the parts that will be exposed to light go through the secondary powder coating process.
8 MECHANICAL WORKING
Our strategy is to produce the combine harvester core components in-house: we want to be sure that they are manufactured according to our high quality standards.
The Drum, Rear Drum, Straw Chopper, and Hybrid Rotor are assembled at three separate stations and then are balanced with special equipment.
Gearbox and final drives components are first worked in dedicated areas and then assembled to form the relevant subgroup. Gearboxes are fully tested in a special booth.
In the Machining Area, two multi-purpose machining centres for axles and other numerically controlled machining centres are located.
9 CUTTING AND BENDING
Cutting and bending are essential parts of our manufacturing process: in order to guarantee a top level quality we have precise and efficient equipment for all these operations.
Also in this department we made very recent investments: the TruBend Series 5000 is TRUMPF’s most successful bending machine worldwide, and has many features that make the operator’s everyday work easier and guarantee optimal part precision and angle accuracy.
In this area we receive all outsourced material from external suppliers such as sheet metal, part moulds, electrical components, hydraulic parts, engines, wheels and small standard parts. The incoming materials are constantly subject to rigorous quality inspections.
The welding operation is crucial for a good working and resistance of the parts. For this reason we continue welding all the main components inside the factory. This is an added value action providing the customers with great benefits.
The Welding Department is composed by 40 welding stations.
A Robotic Island is dedicated to the welding of the Power Flow, Free Flow and L-Series header frames, in various sizes. The system is composed of two robots that move on rails and simultaneously weld the same part assembled on a mechanical hand.
12 AGCO ITALIA
All sales & marketing, accounting, training and after sales service activities for Massey Ferguson, Challenger Valtra, and Fendt, are effected here for the Italian tractor market.
In this department an area is dedicated to the final quality check, another to the fitting of accessories and a specific space to the preparation of the machines with the winter cover: in fact we are the first and only manufacturer in the industry to protect the new combines with an exclusive weatherproof cover during winter shipments that prevents machines from the corrosion by road salt.