Digital Gear Factory

The 4.0 technology showcase and training programme for your resources to make the real cultural leap towards 4.0

The Gear Factory is a real miniature factory where the most advanced 4.0 technologies can be seen applied. It is also used as a learning laboratory that, in a two-day training course, simulates the impact of a lean transformation that a manufacturing company normally carries out over 12 to 24 months. After the processes have been redesigned and improved, which is a preparatory step to implement 4.0 technologies and obtain their maximum benefits, participants transform the Gear Factory into a Smart Factory, by applying the 9 technologies that constitute the Industry 4.0 paradigms.
trainees trained
technology stations
technologies to be applied

A functioning company reproduced to scale to be experienced and improved with Lean principles

Thanks to the highly experiential training methodology using mini workstations to produce electric motors, participants guide the company's transformation according to the Lean logic, learning how to manage the main processes in compliance with the time, cost and quality requirements of the market and applying the most appropriate methodological tools to different situations.

The Lean Transformation course is simulated in four rounds, divided into two days. Participants can experience first-hand how in traditionally organised companies, with production islands and a layout that is not always optimised, the 7 typical wastes of the lean methodology can be hidden: waiting times, stocks, material handling, overproduction, etc.

Participants learn how to measure and analyse the collected data using typical Lean Thinking methods and tools such as the Spaghetti Chart and the Value Stream Map with the aim of redesigning subsequent rounds and streamlining production and information processes.

During the different rounds, continuous improvement is implemented by working in teams:

  • Increasingly sophisticated tools are known and implemented, such as the yamazumi chart
  • The most appropriate methodological tools are applied to different critical situations
  • Analysis of the stock management by applying kanban, supermarket, and on-sight management
  • Issues such as ergonomics and time&methods are addressed

From Lean factory
to Smart Factory

In the last round, the fctory that has become lean is dressed in technology to conclude its transformation into a Smart Factory with a view to digitising the processes already improved in the previous rounds through the application of the nine 4.0 technologies:
Advanced Manufacturing Solution
Additive Manufacturing
Big Data and Analytics
Cyber Sicurity
Industrial Internet (IoT)
Augmented Reality
mappa spazio corsi gear factory

At each of the 10 workstations, participants explore a topic related to applied 4.0 technologies. In addition, they can experiment with certain applications such as:

  • Automatic declaration of production progress
  • Real-time calculation of factory performance
  • Display of information supporting assembly
  • Monitoring parameters with wearable technologies
  • Autonomous internal logistics
logo considi grigio
Our goal is to help increase business competitiveness through an industrial strategy that comes to life from high Lean training, operational excellence, digital and product innovation. A sustainable growth path thati benefits from the new technological opportunities of Industry 4.0.
Via A. De Gasperi, 63
36040 Grisignano di Zocco (VI)
Via San Martino, 7
20122 Milano (MI)
Corso Martiri della Libertà, 3
25122 Brescia (BS)
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CONSIDI S.P.A. (BENEFIT SOCIETY) | Via Alcide De Gasperi n.63 - 36040 Grisignano di Zocco (VI)
C.F./P.IVA 03948220284 | Share Capital: 1.000.000 euro i.v. | Registered in the commercial register of Vicenza number REA VI-307565