Feb. 11, 2008 – Moto Guzzi: Manufacturer mixing tradition with technology

MANDELLO DEL LARIO, ITALY—Nestled in the mountains that tower over Mandello del Lario, Italy, an hour north of Milan, Moto Guzzi continues to manufacture its storied motorcycle line in many of the same facilities built more than 85 years ago.
A tour around the company’s headquarters shows just how fiercely Guzzi has fought to protect its history and tradition through several ownership changes and tumultuous periods since its inception in 1921.
Today, with a workforce of more than 250 employees and several new complexes now replacing many of the original structures, Guzzi is working to combine its history and modern technology into one cohesive unit. After being acquired by the Piaggio Group three years ago, the company has changed many of its operations to improve efficiency and productivity, while at the same time utilizing new technologies.
“The Guzzi name is synonomous with quality craftsmanship and engineering firsts,” said Daniele Torresan, head of Moto Guzzi’s communications department. “Now as part of the Piaggio Group we can maintain that leading edge with the help of their large resources, but at the same time we haven’t sacrificed quality in the process.”

Home Sweet Home

The original Mandello site remains home to the company’s headquarters, the production facility, the historic wind tunnel, the company library and the Guzzi museum, which attracts thousands of visitors from across the globe and features motorcycles and other products that span the company’s history.
When the company was purchased by Aprilia, plans were made to move most of Guzzi’s operations off-site, but it was later decided the move would be cost inhibitive. When Guzzi was acquired by Piaggio, a possible move also was discussed, but Piaggio executives believed the renovation and reconstruction of several buildings would help maintain Guzzi’s brand image better than moving it into a Piaggio facility.
“There are several projects in the works now to renovate or replace existing buildings,” Torresan said. “It’s been a slow process because we’re not moving production off-site, so if one section is under construction, we have to make sure it doesn’t interfere with production capabilities.”

A Manufacturing First

One of the most fascinating aspects of Guzzi’s manufacturing facility is its 57-year-old wind tunnel. The La Galleria del Vento, which was contructed in 1950, was the first wind tunnel capable of testing 1:1 prototypes, allowing the company to market the world’s first motorcycle integral fairing. The wind tunnel enabled racers to mimic real-life riding conditions and optimize their seating and body position at varying racing speeds, which at the time was an unprecedented advantage for racing and production motorcycles.
Although Guzzi bikes are now brought off-site to be tested in modern wind tunnels, the La Galleria del Vento was actually used until 2005, where Guzzi tested the Norge 1200. Aprilia, Guzzi’s sister company, maintains a relationship with the aerodynamics program at the University of Perugia where computer simulations combined with practical tests can more effectively and economically provide accurate testing and feedback. Even though it’s no longer in use, however, the towering structure in the heart of the facility is a daily reminder to both visitors and employees of the company’s proud past.
“When the tunnel was operated in the 1950s and ’60s, it used so much power the entire town would go dark,” Torresan said. “Today, if we turn the tunnel on, we alert the local authorities, so they can alert the surrounding area about the tremendous noise it makes.”
Another strange site on the Guzzi grounds are caves cut hundreds of yards into the mountains that butt up against the facility. Torresan explains during World War II, Mussolini used the Guzzi facility to build machines for his army, and the site was often a target of allied bombings.
“The facility was targeted several times by American and allied forces, but no serious damage was ever done,” he said.

Precision Meets Efficiency

One of the biggest changes implemented at Guzzi in the past three years has been a change in the company’s production line. Guzzi has added a second line in the past year and the move raised some concern that quality would be sacrificed for quantity.
“Technological advances both on our production lines and in our testing areas have speed up the time it takes for the bikes to reach inspection,” Torresan said, “and we’ve been able to adjust production schedules so that we can spend almost as much time tuning and inspecting the bikes as before.”
Torresan adds the changes at the plant have worked out better than anticipated.
“We are a company that is very proud of its past,” Torresan said, “but we’re also very excited for what the future holds, both in terms of our partnership with Piaggio and new products that will continue Guzzi’s proud history.” psb