Production start-up

The production start-up of new vehicles to be assembled by the CKD methodology envisages two related but distinct stages:

  • an initial preliminary stage performed about four months before the manufacturing launch at the Iveco
    company and the relevant plant.

Under the contract agreements, based on the knockdown level requested and the technological level of the licensee company, CKD T.S. and Plant departments involved will start to prepare all the specific technical documentation for the vehicle, its parts and the systems/power tools necessary for assembly (see table below).

The most used documents are as follows:

Lists of indispensable mechanical equipment to guarantee assemblability of the vehicle components

  • Lists of ancillary material necessary to complete the first vehicle
  • Machining cycles derived from the CBU vehicle but netted in line with the knockdown standard
  • Assembly drawings
  • Graphs and drawings
  • Diagrams of electrical and pneumatic systems and braking circuit
  • Assembly check list with sequence of operations
  • Working instructions for specific operations such as programming of electronic control units or various adjustments

And finally the test information, and the files related to Quality Checks and Inspections for the correct application of tightening torque during assembly operations are also supplied.
On-the-job training courses are planned and organised at Iveco plants to teach company foremen/managers and to demonstrate the mechanical equipment and power tools necessary to assemble specific parts and safety organs.. 

  • An operational stage that consists in assembling the first vehicle (prototype) at the company involved; this normally occurs immediately after the arrival of the containers with the materials for the first production lot.

Iveco sends expert personnel to build the vehicle; during each stage of the assembly, the experts give the local workforce all the necessary instructions and technical information.
The length of the training varies and terminates when the company personnel has acquired sufficient familiarity to be able to produce the vehicles on the spot without the presence of the Iveco technicians.
Iveco will clearly continue to provide assistance and support even from a distance, and the local technicians are monitored daily by mail and by telephone / call conference.