Quality and Continuous Improvement
The guiding value of Forghieri’s production system is continuous improvement: working for world leaders is a daily challenge which we take on with cutting-edge management methods.
Quality Policy
Improvement as a Responsibility
We believe in improvement as a concrete commitment involving our people, processes and products. Each goal attained becomes the foundations for a further leap forwards: in quality, safety, and sustainability. We put people and customers first, in the conviction that only an organization capable of learning and perfecting itself constantly can offer long-lasting value and reliability.
Lean Culture
In 2018 we adopted the Lean philosophy, which led us to focus on the activities which generate value for customers, eliminating all potential waste: of time, of materials, of stoppages of raw materials and semi-finished products along the entire process, from supplier to customer.
From this standpoint, at the start of each production shift the employees with responsibilities in the workflow get together for a 15-minute meeting (Asaichi), dedicated to sharing of problems.
Continuous Improvement
For the approach to problem solving both for the development of new products and for products already in production, we adopt the method of continuous improvement (Yuichi), supplemented when required by risk-assessment techniques (inspired by FMEA – Failure Mode and Effects Analysis) models.
Our method of working favors a widespread culture of responsibilization and commitment: each worker is an active participant in our improvement journey, and contributes proactively to the solutions we adopt.
AN INTEGRATED SUPERVISION SYSTEM
Quality as a Constant and Codified Process
The company adopts an integrated approach to quality, closely monitoring every phase of the production and management processes through a structured system which combines quality assurance and supervision. This guarantees compliance with standards, traceability of activities, and continuous improvements in performance, safeguarding the customer and product reliability.
A qualified and suitably sized team follows all phases at close hand, ensuring timely and effective corrective interventions.
The day-to-day work performed to protect customers through application of the 8D and Lean Six Sigma methodologies has allowed us to constantly improve our quality performance, with an average annual reduction in customer compliant rates on bill of sale entries of 19% since 2022.
Inspections Performed
Quality Procedures in the Design Phase
Use of advanced FEM (finite element modeling) software supplemented by solid modeling (CREO) allows us to design every detail with the maximum precision, supported by the Windchill PDM/ PLM system, which allows for structured management of all technical documentation.
The FEM simulations allow us to check that the design of our cabs is correct in terms of ensuring protection from roll-over (ROPS) and falling objects (FOPS). On customer request, these simulations are followed by destructive physical testing on prototypes, carried out both internally and at specialized, accredited testing laboratories. We are also able to develop projects which comply with specific directives, such as the EN 15085-2 standard for the design and manufacture of railway vehicles and components.
Quality Controls and Procedures during the Production and Assembly Phase
We have developed testing and conformity control procedures performed directly by operatives on the line, as well as instrument-based testing and inspection performed by our QC personnel.
As well as calipers, micrometers, and other traditional measurement devices, we use high-precision equipment dedicated to the framework structures and cabs. All this equipment is managed by qualified personnel, who are able to act promptly to ensure compliance with quality standards:
Quickly and accurately acquires the geometry of complex objects, generating digital models useful for dimensional checks and validation. Accuracy: 0.0350 mm.
Allows analysis of the microstructure of welded joints, offering fast, accurate testing directly in the company.
Automatically classifies small components such as screws, washers and brackets, eliminating human error and keeping track of every hardware pack.
Quality Control of Glass for Construction Machinery
At Forghieri, the quality of our glass is ensured by thorough inspections during each phase: both during production, and at the end of the line. Each piece of glass has its physical, optical and mechanical properties checked in order to ensure reliable performance which meets ECE R43 type approval requirements.
We boast a range of instrumentation specifically dedicated to quality control of our glass, such as polarimeter, polariscope, 3D measurement arm, and dark room, as well as equipment for carrying out impact testing for type-approval processes, as well as the 3D scanner for dimensional checks. This instrumentation allows us to meet the strictest requirements of every sector of application.
Six-axis 3D measurement arm
Allows measurement of objects with complex and irregular geometries, even in points which are difficult to access with traditional instruments, allowing the data gathered to be recorded digitally.
Measurement diameter: 3200 mm; volumetric accuracy: ± 0.045mm; repeatability: 0.032 mm
Polarimeter
Allows non-destructive display and quantification of the stresses present in pieces of glass, including those which are not screen printed, ensuring that safe glass is delivered to customers.
Dark room for glass type approval
We guarantee full compliance with the provisions of regulation ECE43 R for type approval of safety glass with a dark room and all optical and mechanical equipment required to ensure machining and processing is correctly monitored and inspected.
FAQ
Polarimeter for measuring stresses, 3D measurement arm for complex dimensional checks, dark room and impact testing equipment for ECE R43 type approval, and 3D scanner for verification of geometries.
Continuous improvement and quality assurance are fundamental elements which cut across Forghieri's entire production process, from design right through to assembly, and the quality controls start out with simulations performed during the design phase right through to checks on the lines.
Through a risk-reduction and continuous improvement process focused on introducing corrective and preventive actions, and through inspections during every production phase, the use of advanced tools, and total traceability of the processes.
Since 2022, we have recorded a 19% annual decrease in customer complaints.
3D scanners, metallographic microscope and small parts scanner dedicated to the cabs.
Continuous improvement and quality assurance are fundamental elements in Forghieri's entire production process, from design through to assembly, and the quality controls start out with simulations performed during the design phase right through to checks on the line.