Mascar partnerships with auxiell to streamline processes and increase production flexibility: setup times cut in half and inventory reduced by 30%
The Vicenza-based company founded by Antonio Maschio, which specializes in haymaking and seeding machinery, has worked with the consulting firm auxiell on production batches, welding robots, assembly lines, and materials management
Faster production changeover times, smaller batches, lower inventory levels, and higher inventory turnover. These are the results of the efficiency improvement project carried out by Mascar, a Vicenza-based company specializing in agricultural haymaking and seeding machinery, thanks to auxiell’s involvement. The project led to a 50% reduction in welding robot setup timeand a 75% reduction in setup time on assembly lines: figures that, on the factory floor, mean greater flexibility in switching between production runs and producing quantities that more closely match actual demand. The inventory turnover ratio rose from 3.7 to 4.7, while inventory levels were reduced by approximately 30%: as a result, materials and products remain in stock for shorter periods and are used more quickly, leading to less tied-up capital, a lower risk of unsold inventory or obsolescence, and more streamlined inventory management.
This approach addresses a key challenge for manufacturing companies: when demand is variable, competitiveness depends not only on increasing production capacity but also on the ability to make existing capacity more flexible and measurable. For companies with a diverse product range, seasonal fluctuations, and international markets, optimizing batches, setups, material flows, and inventory management can become a key strategy for better responding to market demands, reducing the risk of unused capacity during periods of lower demand or operational rigidity during peak periods.
Mascar is headquartered in Grumolo delle Abbadesse, in the province of Vicenza, and manufactures round balers, wrappers, single-seed planters, and in-row seeders. The company, founded in 1998 by Antonio Maschio, manufactures in Italy and exports to over 40 countries.
Mariateresa Maschio, CEO of Mascar, explains: “The project with auxiell was very important because it involved the entire company. It allowed us to work on our organization and processes, which are essential if a company wants to grow. It’s a comprehensive effort that is ongoing and will continue in the coming years.”
The project with auxiell began with a specific production challenge: reducing batch sizes and aligning them more precisely with actual demand, thereby limiting the volume of parts in production, materials not immediately needed, and wait times associated with production changeovers.
The first intervention focused on the welding robot, identified as the main bottleneck. Through an SMED project, setup time was reduced by 50%. The second area of focus involved the assembly lines. Revising the layout and material handling along the line made it possible to reduce setup times by 75% when switching from one model to another.
The initiative also had an impact on inventory management. More frequent procurement, combined with a reduction in “work in progress,” increased the inventory turnover ratio by 27% (from 3.7 to 4.7): this means that materials and products remain in stock for less time and are used or sold more quickly. The approximately 30% reduction in inventory, meanwhile, means less material on hand, resulting in less tied-up capital and a lower risk of unsold inventory or obsolescence. In operational terms, the result is leaner materials management, with less waste and greater overall efficiency in the production system.
The project is now moving forward on two additional fronts: improving the productivity of the assembly lines, with a focus on stabilizing production and optimizing processes, with the goal of making the machines simpler to manufacture while preserving their reliability and quality—fundamental characteristics, especially in the agricultural machinery sector.
