CAMISANO VICENTINO (VI) – Entering Abus ' Maxi Studio is a true experience. The smells, the machinery, the comings and goings of workers, and especially of women workers, as we'll see. Every aspect of this supply chain is engaging and has a specific purpose.
Abus produces its top-of-the-line helmets in this Vicenza-area factory. Maxi Studio is a complex of three large facilities, each of which hosts one of the production processes for the various Abus models. To get a sense of the atmosphere, check out this video.
Inside Abus
During our guided tour of the German company, we followed the entire supply chain. We started with the polycarbonate processing, the plastics from which the actual helmet is formed.
It begins with an endless series of prints and sheets, which then begin processing. This is immediately followed by an initial base coat, designed to withstand the high temperatures of the subsequent thermoforming process. This phase is rigorously monitored by an employee. After a set period of rest, these blades are taken to perhaps the most fascinating department in the entire Abus production system: the thermoforming department.
Here, these sheets are inserted into special machines, and a system called a bubble machine inflates these sheets, making them three-dimensional. An operator then cuts out the inflated part, and the process continues. This moves on to another very important machine, where the shell and the polystyrene part are then joined, creating the helmet structure we see in the actual product.
For the polystyrene part, which isn't properly called that since it's a much more complex material, it's made on a case-by-case basis depending on the model. Various blends are used, in various silos, which are then fed into a special machine. This is the raw material that takes shape.
From raw materials to finished products
The next steps involve applying all the components that make up a helmet. These include straps, the plastic shell, the adjustment dial, and the various fabric and rubber supports for greater comfort.
In the last warehouses, the helmet undergoes final painting and assembly. The fastening clips, the final rubber parts, and any screen printing are then installed. The final step involves preparing the packaging, which will then be shipped to the Abus logistics department, which in turn will handle the helmet's distribution.
It's worth noting that there's also a department dedicated to internal quality control. This department not only carries out spot checks on both evolving projects and models already ready for the market. There are four machines, some reminiscent of medieval torture chambers, which test the tightness of straps, the shell, the MIPS structure, and more.
Women at the center
But if this, in broad terms, is the Abus production process for its top-of-the-line helmets, what we noticed, and what is very interesting, is the great organization of the work. The importance the German company gives to its production process and to the entire supply chain.
Wandering around the factories, the very strong female presence in the Camisano Vicentino plants emerged.
"You've noticed," our Abus guides told us during our factory tour, " that over 90 percent of our employees are women, at least in the actual production department. This is because we've realized they're much better at performing this type of manual, yet precise, work. We're proud to be able to boast this."
The organization of work
As we were saying, at Abus they place great importance on work organization. For example, the final workbench was recently overhauled. We're talking about the final details of the helmet. Previously, the various workers on this workbench always performed the same action. Now, however, each worker performs multiple actions during this process . This process ultimately leads to the helmet's packaging. Why?
"Because," our Abus guides tell us, "we've realized that this way, individual productivity improves. Not only that, but it's also more engaging for the operator, who, by performing more tasks, is less likely to become disengaged. Furthermore, by performing more tasks, the operator is also more versatile when performing multiple tasks. We pay close attention to these aspects, which can improve production and also respect for the worker themselves."
Another example: we use a code to identify which operator performs a specific action. If problems or defects arise in that area, we know where to intervene. And perhaps that operator needs further training. This improves both the work and the operator's condition.
Cleanliness and order are never lacking. They are a constant among the machines, belts, and various areas. Even the cleanliness of the bathrooms is regulated.
To the future
But at Abus, things are big. If you noticed, we mentioned three large factories earlier. Well, given the good performance and high quality of Italian production , the German brand has decided to invest further in our country . A few kilometers from Camisano Vicentino, it has purchased a plot of land measuring over two hectares, and a warehouse of over 10.000 square meters is nearing completion.
"This new facility," Abus leaders continue, "will allow us to significantly improve our production times, even during meetings and pre-production. Simply put, to complete a project, we will no longer have to travel from one location to another or constantly triangulate with another of our facilities located about 100 kilometers away. Everything will be integrated."
"Not only that, but we also have the option to purchase adjacent land, which could potentially allow us to build a logistics hub in the future, thus improving helmet distribution throughout the country . Distribution, for business reasons, is sometimes much more cumbersome, and paradoxically, a helmet made in Italy passes through Germany before reaching the retailer. This could greatly benefit costs and the environment."
