THE PRODUCTION PHASE
Our main office, which also houses our primary production site, is located in the Marche region in central Italy. This area is famous for its rich manufacturing heritage, particularly in the realms of clothing, accessories, and, industrial furniture and woodworking in the north. Our manufacturing facility spans a total area of approximately 18,900 square metres and is partitioned into five primary zones, each aligned with a distinct phase of the production process. These areas encompass two woodworking sections, where initial work is conducted on semi-finished panels; a metalworking segment responsible for processing all metal furniture components; an assembly sector focused on pre-assembled elements; and lastly, a packaging and shipping division.
Office area
The production process starts before the materials
are processed by the machines: during the quotation
phase, the Retail and Hospitality Technical/Sales depts.
design the elements with the aim of optimising
the next production phase. In a second step,
when the opportunity becomes a project,
the area called "Operation", including
the Technical/Engineering, Order/BOM
and Production Planning depts. manages,
in detail, drawings and information
for the production process.
Woodworking
46.200 ft² - Panel sizing and edge-banding
The components production
starts in our factories with the
loading onto the machine, done by an
operator or through robotic arms,
of the "semi-finished" panel. At first
the panel is cut and shaped in the
required sizes and shapes. It is then edge-banded
(the edges see the application of
a plastic or wooden edge strip) and then stored.
The components are now ready, squared
and shaped to the correctly finished dimensions,
to move on to the next stage.
Woodworking
46.200 ft² - MAchine Centers
In this phase, the components,
previously processed by the sizing
and edge-banding machine, are loaded
and bored according to the final features
of the component (holes for hinges,
opening of grooves, etc.). The same machine
can also, in this phase, make the
edge-banding on curved and shaped edges.
Metalworking Manufacturing
43.055 ft² - Metal working/span>
The processing of metal components is
carried out on a dedicated area of 9,000sqm.
This phase involves the manufacturing
of sheet metal elements, aluminium profiles
and stainless steel, which, in a second step,
are assembled with the wooden component
s previously processed in the joinery,
and finally packaged and delivered.
Assembling
45.900 ft²
This phase is dedicated only to pieces that
are shipped fully assembled.
Assembly can be done in two ways:
elements whose size and shape allow
(i.e. kitchen main structure, cabinets)
are assembled by using a machine called
"electromechanical clamp". All the elements
that, unlike the previous ones, cannot be
handled by machine because of their size
and shape (i.e. a supermarket
checkout, the mockup for a hotel),
are manually assembled by four operators.
Packaging
56.600 ft²
During this phase the items are organized
by categories as size and kind of element,
by using bar codes. Then are packed, labelled
and placed on pallet or handled in crates,
and brought to the to the right "loading bay"
(where the items are loaded on trucks then
forward to transport). The machinery that
constitute the packaging line work with items
whose maximum size is l110xd220xh45 cm
, larger ones are handled manually.
Delivery
56.600 ft²
Through barcode readers, every single
barcode printed on the labels placed
on palllets, is read and dimensions and
weight checked. The goods are then loaded
on trucks and delivered. From now, the
shpping iter from the company to their
final customer starts. Thanks to the work
done previously, the goods are traceable.
The client receives the goods and every
pallet or single packaging unit is listed in
an organised packing list.
of aluminium profiles used per year.
of uprights used per year.
of steel sheets used per year.
of edge used per year.
of panels used per year.
boxes shipped per year.
Woodworking
Panel sizing and edge-banding
These images introduce us into the wood panel sizing and edge-banding plant, where the production process begins. It is an Edge-banding machine characterised by automatic feeding and does not require human intervention to turn the elements and change side. This machine applies the edge one side at a time through four steps and can hold up to 36 different edges at the same time of the same thickness. It is a very performing machine, very used for flexyble lots. On the other side, the Double-side edge-banding machine applies the edge on two opposite sides, then the human operator will turn and re-load the piece for the other two sides to be edged. High-performance features and perfect for significant quantities of the same item.
Woodworking
Machining Centers
These views introduce us into the second phase of the woodworking panel: in this phase the elements are loaded and bored according to the final features of the component (holes for hinges, opening of grooves, etc.). From small handywork machinery generally used particularly for small elements not belonging to mass production, to CNC router and edge-bander apart from the shaping of elements, can also accomplish edge-banding and is used especially on curved or particularly-shaped items. The Rem boring machine, it’s a boring machine that open holes on items kept vertically, through automatic conveyors. High-productivity machine that can handle lots of different elements. Finally, Morbidelli FM 400 boring machine has a high productivity, which is approximately 250 pieces/hour. Used for large lots of same items.
ASSEMBLY
Manual assembly and Electromechanical clamp
The assembling phase is dedicated to those elements first assembled and delivered. The Electromechanical Clamp machine used to assemble items that are sold already assembled and whose geometry and sizes (kitchen basic units, cabinets) allow an automatic assembly. In the first part, the various elements of a piece of furniture are placed in the machine with glue and joining parts. The clamps of the machine press the elements together and keep them for the desired time tightening and gripping them. When the item is ready, in the last phase is then completed with parts such as drawers, doors etc. After this the product is ready to be packed, labelled and prepared for delivery. All elements that, due to size or shape, cannot be assembled by a machine (the supermarket check-out counters, or the hotel mock-up room) are instead manually assembled by four operators.
PACKAGING
Packaging department
As the pictures show, the Packaging Department is constituted by a main “conveyor belt”, on which the items move towards a packaging robotic unit, and various “loading platforms”. Every loading platform is specific for item typology or for size (i.e. electric components are handled by one platform only). The human operator does a basic preparation of the items on tray, and applies a temporary barcode. The item is placed on the conveyor and reaches the robotic packaging unit, where the barcode is read, the correct packaging is choosen and the item duly packaged and labelled with the final label, then moved automatically to the loading bay to which belongs in accordance to the order of which is part. All the elements that are part of the same order are unloaded in the same loading bay.
Our team
Mirco Giovanelli
Gibam Group CEO
Marika Giovanelli
CMO & Chief Gibam Composit Division
Giannandrea Tecchi
Operations Head & Production Manager
Marco Bosio
Executive Secretary
Gianpaolo Giovagnoli
IT Manager
Giulia Ricci
Marketing Dept.
Fabiola Piccini
Marketing Dept.
Susanna Tonelli
HR Human Resources Manager
