Skills and capacities were analyzed after the merger between Hatebur and Carlo Salvi in 2016. As a result, the Italians now manufacture electrical cabinets for the smaller machines from the Swiss range. A real success story.

The managers at Hatebur looked admiringly towards Garlate, Italy, after the integration of Carlo Salvi in 2016. The Italians were manufacturing their machines’ electrical cabinets themselves, while the Swiss, after designing and drawing their electrical cabinets, had theirs manufactured externally. “Couldn’t we provide a solution within the Group for our Hatebur machines too?” was the big question. No sooner said than done. After analyzing skills, capacities and possibilities, electrical cabinets for some Hatebur machines are now manufactured in Garlate. This is how synergy works in a positive way.

Collaboration begins with two real tasks

Two specific machine orders were the starting point for this exemplary show of how to make the most of synergies within consolidated companies in the best way possible. A HOTmatic AMP 20 N for manufacturing cam lobes for camshafts was sent to the USA in early 2021. This recently developed press, with a total press capacity of 1500 kN, can produce 200 parts per minute with a diameter of up to 48 millimeters. Plus a HOTmatic AMP 30 S was sent to Russia last year. It is the durable workhorse for medium-sized forgings with a diameter of up to 67 millimeters and a production rate of up to 140 parts per minute. After the division of labor for building electrical cabinets has been set out in concrete terms, the teams get to work. First on the to-do list is selecting the appropriate electrical cabinet. Hatebur designers then define the design according to the capacities required. Country-specific features and customer options are taken into consideration to do so.

South of the Alps, the electrical cabinets are assembled and tested

South of the Alps near Lake  Como, the Carlo Salvi experts construct the electrical cabinets according to the electrical diagram from Hatebur. Based on the parts lists, they purchase components and cables from Reinach, position the electrical components, wire them and test the finished electrical cabinet in an in-house testing center. Managers at both companies are constantly in close contact throughout the process, meaning they can clarify project  issues quickly and unbureaucratically, as well as eliminate potential problems early on. For the Italians, building an electrical cabinet is routine – Carlo Salvi has always been self-sufficient with regard to electrical  technology. For example, coldformers like these are used for manufacturing screws or rivets, always supplied with an electrical cabinet built in-house. The electrical cabinets are assembled, configured, fitted and tested before they are sent to the customer with the machine. This is now a successful process for some of the Hatebur machines too.

Skills and equipment on hand
The electrical warehouse manager at Carlo Salvi first identifies the necessary purchased parts with the department manager and selects suitable suppliers together with the Purchasing department in Switzerland. The assembly manager implements the circuit diagram and plans the important identification of electrical connectors and components. As soon as the ordered material arrives, the conductors and boards are marked with special labels. These are made in-house and are based on the specifications in the circuit diagram. In the assembly phase, technicians and electricians contribute their knowledge regarding diagrams, components, labels and electrical connections. The Carlo Salvi technical specialists can also process sheet metal with the manufacture of brackets, dividing walls and similar in-house. Together with manual expertise, a great deal of dedication, determination and close collaboration with Hatebur colleagues, the result is a recipe for success with potential for the future. Learning phase and digitalization facilitate teamwork – even in challenging times Maurizio Colombo from the Electrical services department enjoys telling the story of how it all began: “When we were asked whether we wanted to be involved in this project, we got excited about it immediately.” In order to develop a mutual understanding of the procedure and features of Hatebur circuit diagrams, the Carlo Salvi experts first traveled to the Hatebur assembly plant in Brugg in summer 2020. “That was very important and fostered collaboration with our Hatebur colleagues, expanding both our knowledge and vision,” remembers Maurizio Colombo. Most importantly, it helped to overcome the initial language  arriers. “Understanding the specialist terminology in a foreign language and translating it was often a huge challenge. But thanks to exceptional teamwork, we were always able to sort out anything that wasn’t clear.”

The coronavirus pandemic made things even more difficult, since face-to-face meetings were often not permitted. Yet Maurizio finds words of praise here too. “In these challenging times, as the Hatebur Group we implemented all of the company’s digitalization systems. The option to inspect the electrical cabinets remotely with our Swiss colleagues was a great help.”

Synergies in a positive way

Since capacities at Carlo Salvi were available with sufficient notice and timely planning, one thing is clear to see from this example: When two experienced and healthy companies merge, synergies can be achieved with an overwhelmingly positive and creative effect.