ABB E-mobility is the division of the ABB Group, counting 100000 employees worldwide, dedicated to electrifying mobility. With 1400+ employees, global headquarters in Switzerland and a state-of-the-art production facility in San Giovanni Valdarno (Arezzo), ABB E-mobility has built over 14 years of world firsts: from Europe’s first 50 kW charger to the world’s first live Truck Megawatt Charger. Their mission is unambiguous: electrify mobility with seamless, efficient, flexible, operated and sustainable charging solutions.

A production line can stop for many reasons, but one of the most frustrating (and most avoidable) is material arriving late or not at all. In ABB E-mobility’s THT production area, the material flow from the supermarket to the line (kitting, replenishment, WIP buffers, feeder routes, point-of-use presentation) currently generates shortages, extra handling and line stops. This project is tasked with solving that.

Starting from a Gemba walk and a spaghetti diagram to map routes, touchpoints and root causes, you will build a current-state material flow map complete with lead times, handoffs and WIP points. From there, you will design the future state: a pull replenishment system with Kanban / e-Kanban, FIFO lanes, standard work for material handlers (milk-run sequence, visual signals, escalation rules) and a supermarket & kitting standard with min/max levels and packaging rules.

The project concludes with a performance dashboard tracking feeding reliability (shortages, stockouts, delivery adherence and material-related line stops), followed by a piloting, training and stabilization phase on selected component families.

If you want to experience firsthand how internal logistics really works inside a high-tech manufacturing plant and are ready to design systems that will actually be implemented, this is your project.

Italian language skills are required for this project.