MR Components leverages intelligent automation to produce high-precision gear components monthly, optimising output with unmanned operations. In an upfront conversation, Alessandro Reguzzo, Founder and MD of the company shares the fundamental philosophy with Team ACI.
Alessandro Reguzzo, Founder and MD of the MR Components
MR Components, a medium-sized company from Grigno, Italy, has significantly increased its production capacity and simultaneously improved quality by introducing intelligent automation with EMAG machines. The company, specialises in the production of parts for differential and planetary gears. It produces an estimated 80,000 components monthly, with partial automation.
Q. Tell us about your journey as an entrepreneur and the inception of MR Components.
A. I am Alessandro Reguzzo, 51 years old and I took the bold step from employee to entrepreneur at the age of 21. It all started in 1995 when I got my first CNC lathe. At first, I worked for a few companies in the region and gradually my business grew.
Q. What led you to buy that first CNC lathe?
A. I started as an apprentice at a nearby company and discovered my passion for precision manufacturing. When I decided to go out on my own, some people thought I was crazy, but I was confident it was the right choice. I took a loan, got my first lathe, and started working in a garage with a CNC lathe. The companies I worked for quickly put their trust in me, perhaps because they saw my passion. Within three years, I already had three CNC lathes.
Q. Who supported you when you set up the company and who were your first customers?
A. My first customers were various craftsmen from the region, including some racing car builders. At first, I made spare parts for local companies, but after a while, I also found larger customers in the north of Veneto.
Q. How has your company evolved over the years?
A. I worked in a garage the size of this office for five years. Then I moved into a small hall and built my first production hall of 2,500 sq. m. in 2006. In January 2024, we moved into our new 6,000 sq. m. building. It is modern and state-of-the-art.
Q. How many employees do you have today and what is the composition of your team?
A. We have around 50 employees, 10 of whom work in the office in the quality department and in technology. The others work in production.
Q. What products do you manufacture?
A. Our two main business areas are the manufacture of components for differential gears and planetary gears. The differential gear parts are supplied complete and ready for installation to our customers. The other product line, which is mainly manufactured on EMAG machines, is planetary gear parts. These are supplied to various Italian customers and above all abroad, with German customers being important customers.
Q. Can you briefly explain your production philosophy?
A. In the beginning, we worked with conventional machines, especially horizontal lathes. Automated production then began with simple Taiwanese vertical lathes, which were within our financial means at the time. After a short time, we realised that the use of automated machines was the key to speeding up production. The main advantage of these machines is that they run automatically and can, therefore, work unmanned. This distinguishes them fundamentally from conventional lathes.
In 2011, we purchased our first two VL 7s from EMAG, which was a game changer for us. Above all, we learned to appreciate the advantages of the integrated measuring probe and the associated in-process control of all components. The stable design and high quality of the machine components are also essential in batch production to stand out from the competition.
Today, all our EMAG machines are equipped with measuring probes so that we can check all components 100 per cent. In addition to in-process control, we carry out further quality controls with various measuring devices. We also have a measuring room equipped with two Zeiss and other measuring machines, so that we can always supply our customers with an optimum product. As you can see, quality is our top priority! We currently have a reject rate of just 0.2 per cent for 80,000 components, which shows that we are well positioned.
Q. It is noticeable that mainly partially or fully automated machines are used, why?
A. In my company, we use different types of manufacturing systems to meet the respective production requirements. In one of our lines, we work with VL 7 machines, where the operator manually places the work pieces on the automation belt. This process has proven to be particularly effective for very simple work pieces or more complex work pieces with small quantities.
In other production lines, we work with VL 4 machines that are equipped with TrackMotion automation. The automation here is very fast and we have greater autonomy, so we can also run the machines in unmanned operation. We work in two shifts and let the machines continue to run autonomously for 2 to 4 hours in the evening, depending on the storage capacity of the raw and finished parts.
We have other manufacturing systems, also with VL 4 and VL 6 machines, which are automated using robots. The decision was made to use a system with robots here, as many components have to undergo other operations in addition to turning, such as marking, which we can carry out very easily and flexibly with the robot.
Overall, these different manufacturing systems enable us to react flexibly to the respective production requirements and ensure high quality and efficiency.
Q. Does this system allow you to utilise the shopfloor even during company closing times, so that the machines continue to run for two to four hours, depending on the work piece, while you and your employees leave for home?
A. Yes, exactly. I have the certainty that if I check all components 100 per cent, the machine will automatically stop production if a part is faulty. That way I avoid rejects and make optimum use of production time. That’s a big advantage because nowadays it’s really difficult to find staff for the night shift. In this way, we have found a way to do without the critical night shift and still benefit from the extra production hours – that’s why we call this time “free” hours.
We can produce batches of 100 to 30,000 components per month. Our batches vary greatly as we have equipped our company to serve different customers with different requirements. We are flexible enough to handle both small and large orders efficiently and on time.
Q. What does your team constitution look like and what role does it play in your company?
A. I consider myself very lucky to have such a strong team at my side. Our long-standing employees in particular, some of whom have been with the company for 20 years, have always believed in me and my vision. They have made a significant contribution to the success of the company, for which I am very grateful. We worked together on the idea of highly automated production. Even though it seemed complex at first, the advantages became obvious over time and we are benefiting from it today. In times of a shortage of skilled workers, a well-coordinated team that accompanies the entire production process is worth its weight in gold. This allows us to guarantee high-quality production and manufacture very economically, even with few staff.
Q. What are your plans for the future?
A. We currently have several projects in the pipeline, including a major project for an international customer. Here, components with a diameter of up to 450 mm are to be machined. To ensure efficient and precision production, we are planning to use two VL 8 machines in combination with robots. This will enable us to supply our customers with a finished component that has been completely manufactured on our machines. We would also like to further develop the technologies of gear cutting and assembly in order to be able to offer our customers even more comprehensive solutions.
Q. What about servicing and maintenance of your machines?
A. Smooth service is crucial for our production. We have an internal department that takes care of proper and extraordinary servicing. In addition, we work with external service providers to ensure that our machines are always in perfect condition. With a production of 80,000 components per month, we cannot afford any downtime. ACI
