FPT Industrial’s Foggia factory produces six million engines

Six million engines is the goal achieved by the Foggia factory of FPT Industrial, which has about 1,700 employees and an annual production capacity of 325,000 engines and 400,000 engine shafts.

The production of engines for light commercial vehicles began at the Foggia location in 1977, with the 8140 Series, known as Sofim engines, which continued until 2006 and resulted in four million units leaving the production lines.

Thanks to their versatility and reliability, the 8140 Series engines, with a capacity of 2.5 and later 2.8 litres, have been used over the years for a variety of applications, from light commercial vehicles with clients such as Iveco, Renault and Fiat Auto, to the marine and power generation industries.

The ‘light-duty’ mission of Foggia was confirmed in 2000 when F1 Series engines went into production, initially with the 2.3-litre version until the introduction of the 3.0-litre version in 2003.

These highly successful engines, of which so far two million units have been produced, have been chosen by prestigious marques for their light commercial vehicles, such as Iveco for the Daily, Sevel for the Ducato and Daimler for the Mitsubishi Fuso Canter.

The F1 Series, with its four-cylinder engines of 2.3-litres (F1A) and 3.0-litres (F1C) displacement, ensures optimum efficiency and minimum oil consumption, together with long service intervals. The engines, with power ranging from 71 to 150 kW (97-204 hp), are equipped with a second generation Common Rail injection system, which allows for maximum torque, higher power and lower fuel consumption. The engines are compliant with Euro V, EPA13 and JP09 and, in the methane (CNG) version, with Euro VI.

Since 2001 Foggia has also produced engine shafts, which are used not only for F1 engines, but also for those of the NEF and F5 Series in Turin and South America.

Like all FPT Industrial factories, Foggia is also implementing World Class Manufacturing (WCM). WCM is a structured and integrated production system that encompasses all the processes of the plant, from safety to the environment, from maintenance to logistics and quality. The goal is to continuously improve production performance, seeking a gradual elimination of waste, in order to ensure product quality and maximum flexibility in responding to customer requests, through the involvement and motivation of the personnel working in the factories.

World Class Manufacturing activities are formally audited at regular intervals and each factory is assigned a score and the appropriate prizes (Bronze, Silver, Gold) during these audits.

In the context of this process, FPT Industrial’s Foggia factory won Bronze in 2012 and is striving to reach the next level of Silver in 2014.