COMAU has implemented its in.Grid Robot Monitoring platform at IVECO’s Valladolid facility in Spain to enhance production efficiency.
This cloud-based system, specifically designed to improve operational visibility and maintenance efficiency, is part of IVECO's broader industrial digitalisation strategy. The implementation focuses on monitoring COMAU robots deployed in the Door Ring and Mascherone assembly lines.
Enhanced operational insight
The in.Grid platform autonomously collects production and process data, identifies performance deviations, signals anomalies, and checks user-defined KPIs. This combination of statistical and trend-based analysis aids IVECO’s engineering team in optimizing robot utilisation, minimising unexpected downtimes, and enhancing process reliability.
Flexible production design
In line with COMAU's comprehensive approach, the project was executed using simultaneous engineering
In line with COMAU's comprehensive approach, the project was executed using simultaneous engineering, which involved the installation of both Framing and Door lines.
These lines, incorporating a flexible production concept, feature the COMAU-supplied geogripper Framing line with a ring-shaped layout aimed at reducing non-value-added stations and maximising efficiency. COMAU’s proprietary table-top standard was applied in the Door line development, both employing COMAU robots and the Versa Pallet transport system.
Optimising maintenance scheduling
Integrating in.Grid into IVECO's existing infrastructure has created a cohesive digital environment that supports proactive maintenance and informed decision-making. The platform processes extensive data volumes from robot controllers, delivering a detailed understanding of each robot’s performance, status, and maintenance requirements.
Additionally, in.Grid's capabilities include asset management and variable tracking, enabling IVECO to visualise trends, monitor spot-welding parameters, and improve maintenance scheduling. This intelligent, scalable solution is ready for future expansion while preserving data integrity and user experience. COMAU is also working on enhancing the solution's scalability with artificial intelligence integration.
Global production enhancements
Giuseppe Daresta, the Head of Advanced Manufacturing Solutions & ESG at IVECO Group, remarked on the shared innovation within the long-standing partnership, “The in.Grid platform is a key milestone in our digital transformation, enabling predictive maintenance, improved asset performance, and greater efficiency and sustainability across our global production network.”
Boosting production processes
Giovanni Volpes, Chief Extended Europe Officer, emphasized, “Digitalisation is a key element for improving production processes. Our latest solution, in.Grid, provides an advanced layer of digital intelligence to the industrial setting, and we are delighted to see our technology implemented by such an innovative and longstanding partner like IVECO.”
The high-frequency monitoring combined with predictive analytics helps manufacturers like IVECO improve production efficiency and achieve process stability.
Proactive performance monitoring
in.Grid offers significant advantages with its proactive performance monitoring and analytics
in.Grid offers significant advantages with its proactive performance monitoring and analytics, aiding manufacturers in anticipating and resolving production issues before they arise. Its flexible architecture ensures adaptability to different plant sizes while maintaining cost-efficiency through a subscription model. By boosting process visibility, in.Grid lowers maintenance costs, reduces downtime, and enhances production reliability, extending the lifespan and performance of robotic fleets.
The installation’s success at IVECO Valladolid highlights COMAU’s dedication to delivering intelligent automation solutions that foster performance improvements, sustainability, and operational resilience.
Continued excellence in industrial production
The IVECO factory in Valladolid, a longstanding industrial site, produces the light commercial vehicle Daily and the heavy-range cabs, reinforcing its role as a benchmark for efficiency and employment in Castilla y León.
Celebrating the production of the 700,000th unit of the Daily in 2022, the plant continues to be a model of success and innovation, recognised for its Industry 4.0 commitment and dedication to digital transformation.
COMAU has deployed its in.Grid Robot Monitoring platform at IVECO’s Valladolid plant in Spain, helping support the customer’s industrial digitalisation strategy. Developed to enhance operational visibility and improve maintenance efficiency, the cloud-based system monitors COMAU robots on IVECO’s Door Ring and Mascherone assembly lines.
COMAU’s in.Grid Robot Monitoring system autonomously captures production and process data, identifies performance deviations, signals anomalies, and verifies user-defined KPIs. This statistical and trend-based analysis helps IVECO’s engineering team optimise robot utilisation, reduce unplanned downtime, and strengthen overall process reliability.
Flexible production concept
Aligned with the company’s comprehensive approach, COMAU supported the IVECO project through simultaneous engineering efforts that included installation of the Framing line and the Door line.
Not only were both lines designed with a flexible production concept, the COMAU-supplied geogripper Framing line features a ring-shaped layout engineered to minimise non-value-added stations and maximise efficiency. Similarly, for the Door line, COMAU applied its proprietary table-top standard during the development process. Both the Framing and Door lines utilise COMAU robots and its Versa Pallet transport system.
Improving maintenance scheduling
By integrating in.Grid within the existing automation infrastructure, IVECO has gained a unified digital environment that supports proactive maintenance and informed decision-making. The platform’s capacity to process large volumes of data directly from robot controllers ensures a detailed understanding of each robot’s status, performance, and maintenance needs.
Alongside its monitoring capabilities, in.Grid offers asset management and variable tracking functions, allowing IVECO to visualise historical trends, monitor spot-welding parameters, and improve maintenance scheduling. Furthermore, the intelligent and scalable solution supports future expansion across additional robots, lines, or plants while maintaining the same data integrity and user experience. In tandem, COMAU is working to enrich the advanced scalability of its robot monitoring solution through the enhanced integration of artificial intelligence.
Global production network
“IVECO and COMAU share a long-standing partnership based on industrial excellence and innovation. As a leader in automation, COMAU has supported the evolution of our manufacturing footprint toward more digital and resilient operations,” said Giuseppe Daresta, Head of Advanced Manufacturing Solutions & ESG at IVECO Group.
“The in.Grid platform is a key milestone in our digital transformation, enabling predictive maintenance, improved asset performance, and greater efficiency and sustainability across our global production network.”
Improving production processes
“Digitalisation is a key element for improving production processes. For this reason, COMAU is dedicated to driving the development of cutting-edge technologies in this area. Our latest solution, in.Grid, provides an advanced layer of digital intelligence to the industrial setting, and we are delighted to see our technology implemented by such an innovative and longstanding partner like IVECO,” emphasised Giovanni Volpes, Chief Extended Europe Officer.
“By combining high-frequency monitoring with predictive analytics, the system helps manufacturers like IVECO increase production efficiency and achieve greater process stability.”
Proactive performance monitoring
The in.Grid platform delivers clear operational advantages, including proactive performance monitoring and analytics that help manufacturers anticipate and resolve issues before they affect production. Its flexible architecture ensures adaptability across different plant sizes while maintaining cost efficiency through a subscription model. By improving process visibility, in.Grid reduces maintenance costs, minimises downtime, and enhances overall production reliability, extending the lifespan and performance of the robotic fleet.
The successful implementation at IVECO Valladolid reflects COMAU’s commitment to delivering intelligent, connected automation solutions that empower manufacturers to achieve measurable improvements in performance, sustainability, and operational resilience.
Light commercial vehicle
The IVECO factory in Valladolid is an industrial plant with more than six decades of history where both the light commercial vehicle Daily and the cabs of the heavy range are produced, consolidating itself as a benchmark for efficiency and employment in Castilla y León. In 2022 celebrated the production of the 700,000 unit of the Daily, which reflects the continuity and success of its productive activity.
The plant has been recognised for its commitment to Industry 4.0 and continuous improvement, receiving several awards for its innovation and digital transformation.
