Where bicycle manufacturing meets industrial intelligence

Quindi supports Bianchi in building the digital architecture behind its new production plant: tracked progress, guided operators, and measurable industrial performance.

BicYCLES

MANUFACTURING

Production target

The plant operates at full capacity while maintaining its target of 500 bicycles per day, even with different orders, greater product variety, and increasing customization requirements.

Data governance

ERP, WMS, assembly data, and production information converge into a single interconnected operational flow, readable and updated in real time.

Operational visibility

Every bicycle, phase, and workstation leaves a readable trace: progress, timing, activities, and issues become useful data to control and improve production.

Context

For more than 130 years, Bianchi has been part of bicycle history, with an international presence across racing and everyday bikes. In 2020, the company launched a new production plant with a clear objective: bring industrial capacity closer to the heart of the brand and bring the plant up to full operating speed. The challenge came from a production environment that was becoming more demanding by the day: greater product variety, smaller batches, increasing customization, and a target of up to 500 bicycles per day. Producing more was no longer the whole point. Bianchi needed a plant able to stay fluid and resilient, even as every order became less standard than the previous one.

Challenge

500 bicycles per day,
with growing variety.

Bianchi had set a precise production target for the new plant: reaching up to 500 bicycles per day while managing greater product variety, smaller batches, and demand increasingly driven by customization.

The challenge was to make that number sustainable in day-to-day production by coordinating planning, assembly lines, material availability, workforce allocation, and order progress.

To make it work, Bianchi needed a digital architecture able to connect ERP, WMS, automated lines, BI, and production data into one live operational flow.

Quindi Approach

From live data to operational decisions.

To bring the new plant up to full operating speed, Quindi connected assembly lines, ERP, WMS, RFID, production data, and shop-floor workstations into one digital flow.

On top of this foundation, Quindi’s AI acts as an operational support layer, built on live shop-floor data: helping teams plan, balance, detect anomalies, access KPIs, and turn factory events into useful guidance for both line operators and plant managers.

Integrating
the flow

Quindi connects automated assembly, ERP, WMS, RFID, and production data into a single operating system. Orders, materials, workstations, and progress no longer remain separate pieces of information: they feed the same live data foundation.

Automatic
tracking

Each frame is associated with a production order and becomes a unique production unit. RFID tracks its movement in and out of workstations, making progress visible without manual data entry.

Synchronizing
the production flow

Quindi supports order planning, line balancing, and workforce management. Its AI helps interpret constraints, priorities, and operational capacity, making the production flow more continuous and controlled.

Operational intelligence

Quindi makes data, KPIs, and process information available when they are needed: at the workstation, through dedicated interfaces, or even on mobile. The goal is not to review reports after the fact, but to understand what is happening while the process can still be changed.

Risultati

Return on AI,
produced on the shop floor

With Quindi, Bianchi’s new plant reached and maintained its production target across changing operating conditions. At the same time, Bianchi gained a more continuous way to read production, coordinate activities, and intervene before anomalies turned into costs.

This is what Return on AI means for Quindi: operational return generated every day, inside a tangible environment like the production line.

500
‍Bicycles per day

Production target reached and maintained, even with greater product variety, smaller batches, and increasing customization.

+14%
‍Efficiency

Machine states are monitored across working time, setup, idle time, errors, and micro-stops.

-20%
Rework

Traceable control across kitting, components, and configuration reduces the risk of errors before production of each individual unit begins.

+12%
Internal quality control

Process deviations are detected as they happen, with data and analytics that help read anomalies, recurring issues, and operational patterns.

One-piece flow traceability

Each frame becomes a unique production unit: order, workstation, components, and progress remain connected to the individual piece.

Operational intelligence

Live data and AI analytics help managers understand production performance while it happens. KPIs, anomalies, delays, and critical signals become actionable information before they become operational costs.

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Where bicycle manufacturing meets industrial intelligence

Quindi supports Bianchi in building the digital architecture behind its new production plant: tracked progress, guided operators, and measurable industrial performance.

Context

Challenge

Quindi Approach

Integratingthe flow

Automatictracking

Synchronizingthe production flow

Operational intelligence

Risultati

Contact us

Funding, grants & subsidies

Integrating
the flow

Automatic
tracking

Synchronizing
the production flow