Implementing Lean 5S in the Carbon Fibre Cutting Process: Downstream Effects on Lamination at Dallara Compositi S.r.l.

This thesis describes the internship experience conducted from April to Semptember 2025 at Dal- lara Compositi S.r.l., a leading company in the design and production of composite material com- ponents for the motorsport and automotive sectors. The purpose of this work is to present the process that guided the implementation of the 5S system in the carbon fibre cutting department. This project aimed to optimize the production flow and ensure that the product output aligns with the market-defined Takt Time: this has been achieved by applying the methodologies and tools of the Lean Production System, adapted to the specific capabilities and needs of the company. In the initial part of the thesis, the company’s history and the economic context in which this project was carried out are introduced: the organization of the Dallara Group is presented first, followed by an analysis of the current market and its demands. Following this introductory section, the central part is focused on the approach used to develop the 5S model, beginning with an analysis of the department’s initial state and its existing problems related to the layout and internal work process, continuing with a detailed description of the steps applied and the introduction of new tools to streamline and accelerate the production process. This section is immediately followed by an analysis of the impact that the 5S system had on the next department in the production process: lamination. It highlights the strong correlation be- tween the two departments and emphasizes the importance of a synergistic company-wide system to maintain an excellent quality standard as required by the client. The project concludes by presenting the results obtained: the outputs before and after the renewal project are analyzed, thereby confirming the achievement of the predefined objectives. Ultimately, the experience validates the adopted approach, underlining the crucial role of systematic optimiza- tion in ensuring concrete and lasting improvements. This aspect becomes even more significant when considered in light of today’s business environment, which is increasingly marked by contin- uous transformation and rising production volumes.