AUTUMN 1997
The management of the central purchasing office of the Turin Automotive Group contacted Roberto Stola to understand the availability of Stola s.p.a. for an important industrial initiative to be carried out in Brazil.
A substantial commitment was required for the supply of sheet metal stamping, assembled subgroups and complete raw bodies, related to the Palio family vehicles which would need to be delivered "just in time" for painting and final assembly in the nearby Fiat factory.
South America and Brazil in particular, were becoming one of the most important markets for the automotive sector, Fiat, Volkswagen and GM Chevrolet were leaders of this immense commercial region known as Mercosur.
Fiat's goal in that part of the world was therefore to increase its production, grow in quality and above all to insert specific new models suitable not only for South America, but also other emerging markets around the world.
The correct name for Fiat in Brazil is Fiat Automoveis S.A., more commonly nown by the acronym FIASA.
The headquarters and large production site were in Betim, a town in the metropolitan area of ??Belo Horizonte; the Chief Executive Officer at the time was Engineer Giovanni Razelli who had also held the role of "Superintendent" since 1996.
Since the beginning in 1992,Technical responsibility for the Palio projects was entrusted to Engineer Luigi Sburlati through the so-called "Fiat 178 Platform".
The Fiat Palio had been built in Brazil since 1996, with new production sites were gradually added in Argentina, Venezuela, Poland, Turkey, Morocco, South Africa, India and China.
These were be the countries where Fiat's first "World Car", known by it's code name Type 178-A, were produced.
The involvement of Stola s.p.a. was required not only for the construction of a molding and assembly factory for raw shells, but also to deal with the product engineering of all future generations of Palio family vehicles in a six-year plan starting from the end of 1997.
Roberto and Alfredo Stola therefore decided to support the proposal by creating a new company, 100% owned by Stola s.p.a., to be known as "Stola do Brasil".
The trademark was the traditional rhombus but in green, in tribute to the Brazilian flag.
This entrepreneurial choice esured an extraordinary amount of work in the engineering design sector, which consequently led to the creation of models, mathematical surfaces, master models, prototypes and assembly masters.
It must be noted thatover time Fiat Auto required that "a part" of these specific engineering activities were carried out locally in the offices of the Stola do Brasil factory in Belo Horizonte.
The six-year work program included the complete development of a pick-up based on the Type 178-A chassis in two configurations (short and long cab), whose start of production for raw bodies was scheduled for August 1998 .
Over time, these pick-ups included restyling work known as Type 178-2 to be launched on the market in 2001, and Type 178-3 in 2003, both alwaincluding all the various versions.
Stola spa, through its Italian reference banks, procured loans of 50,000,000,000 lire to invest in Stola do Brasil, whose operational headquarters were in the city of Belo Horizonte at Anel Rodoviario BR 262 Km 21.5 Bairro Dona Clara Belo Horizonte, Minas Gerais State 31255-375.
This substantial sum of money was necessary not only for construction work and infrastructure, but also for all means of work, press lines, equipment, machinery, production start-up and staff,including their training.
The numbers are impressive, in fact the targets shared with Fiat included a covered work surface of 80,000 square meters, 760 employees, and a processing of 35,000 tons of sheet metal per year and a plan to install three complete lines of presses.
For tall construction work, including plants, Stola entrusted the works to the construction and plant company Fiat Engineering, with an agreement signed in November 1997, a necessary choice in order to respect the timescales agreed in the contract.
In essence, every organizational and operational aspect both for the building works of the plant and for those relating to the engineering and tooling product of the two Palio Type 178-A pickups would start at the beginning of December 1997.
Roberto Stola concentrated first hand on this effort,assisted by Engineer Carlo Alecci, Doctor Carlo Biassoni and Marco Goffi and many other technicians with dozens and dozens of flights to Brazil, working together every single day to maintain this extraordinary commitment.
At his side as deputy Cavalier Guido Maina, former manager of Fiat Auto Technologies in Turin, an expert in the South American industry and above experience of management in the construction and operation of large factories.
For the immense work related to the construction of the building structures, the technical systems and the start of production, Engineer Alecci, convinced his former colleague Engineer Alvaro Puglisi to leave Comau and join the managerial team in February 1998, moving to Belo Horizonte for two years.
Under the very particular attention of Roberto Stola and his Italian team, the management were selected who would become to be permanently resident in Brazil; Enrico Negri for production, Celio De Castro for staff, Giuseppe Facchin for stamping, Arturo Vidal for paneling, Giancarlo Zago for quality, Pauline Wooley for management control and Marcus Pacheco for administration.
Puglisi had experience in the construction of the means of work and equipment necessary for the production start-up of the bodywork assembly lines; in addition to this, he was also be asked to assist Cav. Maina for every construction aspect contracted to Fiat Engineering.
Bisogna immaginare che la partenza di tutto è un terreno selezionato da Fiasa di 200.000 metri quadrati in una zona boschiva e particolarmente umida.
Alvaro Puglisi per tutto il tempo trascorso a Belo Horizonte potrà sempre contare sul supporto giornaliero di Roberto Stola, Alecci, Biassoni e Goffi oltre che della Direzione della Stola do Brasil.
It is necessary to imagine that everything began with a 200,000 square meter tract of land selected by Fiasa in a particularly humid wooded area.
Alvaro Puglisi for his duration in Belo Horizonte could always count on the daily support of Roberto Stola, Alecci, Biassoni and Goffi as well as the management of Stola do Brasil.
The two Strada-type pickups of the Palio 178-A family was the first ambitious goal, and in this phase, given that the plant in Belo Horizonte was far from completed, any technical development work aimed at it's engineering and modeling and related activities would be carried out at Stola spa in Rivoli, with the support of the Cinisello Balsamo office.
The production equipment, such as molds, assembly lines and their related design was ordered directly by Stola s.p.a. from SAT in Beinasco, a company owned personally by Roberto Stola which he founded in 1968, and whose operations, both in Italy and in Brazil, were handled by Marco Goffi.
In parallel with the construction of the Stola do Brasil plant, the development of product engineering and the construction of the means of production, another immense work is needed; the supply of press lines to be shipped to Brazil and then put into operation within the plant.
In Rivoli, Stola rented a two-storey building in via Ivrea 86 right next to its headquarters, to house an important group of engineering technicians dedicated to the pick-up project, essentially a work space that took the name of "Palio Platform.".
The purpose of this building is to host Fiat and Stola members as a single team, in order to simultaneously carry out all the design activities of the bodywork, chassis, interiors, electronics, electrical and structural calculations.
It was a very innovative way of working at the time and became known as "simultaneous engineering", the purpose of whiuch was to involve each supplier of parts and systems of the project from the beginning of the engineering together with the car manufacturer.
This first project went on to be marketed under the name "Strada" in both the short and long cab versions and was styled by Giorgetto Giugiaro.
The Project Manager of Stola for these two commercial vehicles is Pierangelo Bergamasco under the direction of Gottardo Bustreo.
Gianfranco Morlacchi, head of Stola's "Information Systems", went on to coordinate IT for over six years with Fiat / Fiasa including all the other plants around the world where the Tipo 178 was produced.
This ensured that the IT technical language was univocal and in line with project standards requested by the customer.
In particular, the network infrastructure shown in the image below was built with the Systems Team composed of Massimo Cafasso, Claudio Cavalotto, and Sergio Antonaccio.
The interconnection between the Stola offices in Italy, those of Belo Horizzonte and Fiasa in Betim allowed the real-time transfer of mathematics from Italy to Brazil and vice versa.
This system made possible the meetings necessary for the correct development of the project, and not secondary due to the difference in time zones, it also allowed the optimized use of the expensive software resources available in the various locations.
Returning to the two pick ups, it must be said that all the front part including doors and interiors are derived from the Tipo178, a two-volume hatch back, the chassis however required important technical changes, especially in the central and rear part to increase its robustness given it's different use. including modification to the shock absorbers.
In the meantime, since the beginning of January 1998, the construction work of the Stola do Brasil plant proceeded at a pace. 180 Fiat Engineering construction workers in three shifts, 24 hours a day, seven days a week and with the help of photoelectric cells allowing work through the night.
75% of the construction works would have to be finished and usable to instal the various pick-up production lines no later than the end of the summer, required to fulfill the commitments made in Turin with Fiat management.
For the construction company Fiat Engineering, the situation was so extreme that, unable to source special steel alloy beams to brace the plant roof in South America, they will had purchase them in Italy and organize a dedicated cargo flight from Milan Malpensa to Belo Horizonte by renting an Antonov AN 124 plane.
The supplier of the special beams was Acciaierie Verona s.p.a., which delivered 100 tons of finished prefabricated material; the landing of the giant Russian freighter in Belo Horizonte did not go unnoticed, and the news was reported in many local newspapers.
Less than ten months after the beginning of the construction / plant engineering works, and the start of the design and production equipment installation for the 178-A picks, on 3 August 1998 Roberto Stola ,Carlo Alecci and Carlo Biassoni flew, in a MD11 of the Varig company of Brazil, to attend the production start-up of the plant.
They were welcomed to Stola do Brasil by Newton Garzon, Guido Maina, Alvaro Puglisi and Enrico Negri to assist in the assembly of the first 50 chassis which were then be bodied in the following week.
In view of the target reached, Fiasa and Stola do Brasil organized the official inauguration on 29th September chaired by Roberto Stola and Carlo Alecci for Stola s.p.a. and Gianni Razelli and Jonas Carvalho for Fiasa.
The most important local entrepreneurs and city authorities of Belo Horizonte and the state of Minas Gerais were present at the event.
On 24 October 1998 at the São Paulo motor show, the two Palio Strada pickups were be presented as world premier, and the start of the actual sale was announced as the end of November as planned from the beginning, thus reaching the established goal.
In November 1999, Fiat Auto asked Stola s.p.a to design the restyling of the first series of Palio currently in production. The target was to start marketing the new versions from the beginning of autumn 2001; it wouldbe known by design code Type 178-2
The versions were the classic hatchback, the Weekend station wagon, the Siena hatchback and the Strada double cab pickup.
The design was by Giugiaro, and the restyled parts included the two bumpers,bonnet and front fenders, the tailgate, all the light units and a part of the interior introducing airbags and an automatic gearbox.
In January 2000, Fiat Auto in Turin entrusted the position of CEO of Fiasa to Engineer Gianni Coda, manager of the Group Fiat Ferroviaria.
On 13 June 2000, during the Turin Motor Show, Alfredo Stola learned that he would have to represent his Uncle Roberto in a meeting with the CEO of Fiasa in Brazil.
The important appointment scheduled for mid-May was to discuss the thorny problem that arose three months earlier due to the high cost of sheet steel used in Stola do Brasil at a volume of around three thousand tons per month.
The meeting with Engineer Gianni Coda will take place in his office in Betim on the morning of June 15, and the discussion for the prices of raw materials will focus on finding an agreement with the Usiminas steel mills, a Fiasa approved supplier.
It was a difficult meeting as Alfredo had never been involved in the construction and management of Stola do Brasil, and the losses generated monthly by the raw material were enormous.
In the end, a sufficiently satisfactory agreement for both parties was found at the end of the meeting.
Once the Superintendent Cavalier Maina has been personally informed and Doctor Biassoni has been reached on the phone in Rivoli, Alfredo left for Italy on an afternoon flight; it was his first trip ever to South America.
Franco was Roberto Stola's first cousin as their respective grandfathers were brothers.Having managerial experience between the United States and Italy gained in the companies Teksid, ITT and ABB, made us think of him as a choice.
In the meantime, the production of both versions of the Strada pick-ups, went ahead at maximum capacity with about 200 bodies delivered per day " just in time" to the Fiasa plant in Betim, through the use of dozens of trucks set up as car transporters departing from the Stola do Brasil every 15 minutes.
Even the moulding and assembly of many subgroups for the normal type Palio first series 178-A in various versions were produced, transported and delivered in the same way; among the most significant units were the complete engine compartment, the doors, the hatches, and the internal wheel arches.
At that time, additional unforeseen design resources were also requested to assist "Fiat Auto Argentina" in starting production of the Siena 178-2 three-volume version.
Carlo Carena took care of it with a long trip to Cordoba working in collaboration with the Argentine technicians of Fiat.
In October 2001, in the Fiasa plant, two years after the start of design activities carried out principaly in the technical offices of Stola in Rivoli, the production of the restyled Palio 178-2 gradually began in all it's four versions.
This moment coincided with the change to the Technical Management of the Fiat Palio platform, the position of Engineer Luigi Sburlati, having reached retirement age, was taken over by Engineer Piero Grillo, former Fiasa man in charge of purchasing.
The production start-up of the 178-2 made the Fiasa management decide that for logistical reasons it is more convenient to move the small assembly line of the Fiat Fiorino raw bodies to make internal workflows more efficient; Stola do Brasil came to mind.
For the Stola company it is an unexpected and great opportunity, it is well known that this commercial vehicle sold also in Europe having a production rate of about 70/100 units per day wass too small for Fiasa but perfect for the Stola do Brasil.
A few months after the start of production of the Fiorino bodies, came another great but unexpected request to Stola do Brasil; to include new production of raw bodies for the Fiat Doblò in the Strada pick-up lines.
With a forecast of 170 units per day, this order would lead to near capacity production for the plant, taking into account the further stamping and sub- assemblies.
As for the pick-ups and all the Palio versions, the logistics of the raw bodies of the Fiorino and Doblò also used a just-in-time delivery technique using car transporter trucks.
At the Rivoli headquarters, six months before the Palio 178-2 went on sale, evidently urged by the Fiat / Fiasa management, it was decided to speed up the start-up of the design office inside the Stola do Brasil as had been requested at the beginning.
On April 18, 2001, on the occasion of the usual scheduled trip to Belo Horizonte, Roberto Stola accompanied by Engineer Alecci, Dr. Biassoni and Engineer Carpegna, had "Stola Engineering do Brasil" on his agenda.
Gottardo Bustreo and Carlo Biassoni asked Roberto Arpini from the Stola design office in Cinisello Balsamo to anticipate his presence in Brazil by a week to better organize the important meeting on site.
The necessity for this on the part of Fiasa was the imminent start of engineering work for the complete future range of the new Type 178-3 family in numerous versions which was to begin sale at the end of 2003.
The construction of a technical office building was thus established within the same area Stola do Brasil.
The company "Stola Engineering do Brasil" was born, 100% owned by Stola do Brasil and technically directed by Roberto Arpini. Superintendent was Cavalier Guido Maina, who back on the scene having been freed up from the personal commitments that had held him back for a year and a half.
A job training course was immediately set up in collaboration with Isvor Brazil, which would also be responsible for finding young graduates from technical schools in Belo Hotizonte.
The building was inaugurated in October 2001, and the staff of Stola s.p.a. in permanent transfer, as well as Arpini ,Papalia, and Salvatore Tuvà, was made up of Carlo Carena, Andrea Giovannelli Paola Busato, Paolo Zerbini, Alessandro D'Apuzzo, Gianluca Guarnaschelli, Alberto Mancini, Fulvio Bracco, Denis Pace, Roberta Passione, Alessandro De Zanni, Gianluca Monfrino, Giuseppe Papalia, Alessio Fucci, Potito Gagliardi, Italo Paganotto, Mariateresa Savatteri, Laura Faccenda, Silvia Vittone, Giorgio Negro, Stefano Marchio, Alberto Ferranti, Massimiliano Cudia, Roberta Passione and Federico Croci.
In advance,Celio de Castro, personnel director of Stola do Brasil organized the best welcome for them, and to make the distance less uncomfortable, about twenty apartments were rented in the Savassi residence in Rua Alagoas 581 in the center of Belo Horizzonte.
A modern and well equipped accommodation with concierge, security service, laundry, swimming pool and volleyball court, with the convenience of being only 200 meters from a shopping center.
Not least it had the advantage of being able to reach the technical officeby car in twenty minutes and the Fiasa plant in 45.
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For the Directors and managers of the Stola s.p.a and Sat spa. De Castro selected an exclusive hotel in the center of Belo Horizonte called “Ouro Minas” by negotiating a very convenient corporate rate.
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The Stola Engineering do Brasil team interfaced with the Fiasa / Fiat men directed by the Engineer Piero Grillo: Claudio Demaria, Ugo Delfino, Aroldo Borges, Marcio Tonani, Carlos Augustos, Alexandre Abreu, Leonardo Quadros, Robson Cotta , Gianni Gramiglia, Marco Limoncelli, Flavio Penna, Giovanni Biolatti, Claudio Pagliero, and Saglietti Piero, Giuseppe di Stasi, Giuseppe Marinaro, Piero Benedetto and Bruno Pastorelli.
The engineering works of the 178-3 began in December 2001, with the target of starting series production in Brazil in November 2003, following gradually in the other plants around the world.
The work in the new building of Stola Engineering do Brasil was for the most part carried out using Catia 4 software for the design and Codep for the Bill of Material.
In order to carry out this immense work on the 178-3 and considering the many versions (2 Volumes, Sedan, Station Wagon, and Pick Up short and long cab), another 50 Brazilian design engineers were hired to support the Italian team.
Pasquale Papalia from Belo Horizonte together with Salvatore Tuvà in coordination with the technicians of the Stola headquarters in Rivoli required that various activities had to be performed directly in Italy, such as the development of mathematical surfaces, master models, assembly masters and the first prototypes.
This is partly due to the fact that the design of all these different variants of the Fiat Palio Tipo 178-3 were the fruit of Italdesign's work, and the visits to Rivoli by Giorgetto and Fabrizio Giugiaro and their collaborators for the various approvals in virtual room and in the modeling shop were frequent.
In fact, Massimo Stola assisted by Carlo Mantovani, worked in agreement with the Giugiaro family, to develop the best possible mathematical surfaces, which were then verified on the CNC milled master models, also in Stola, under the supervision of the foreman Vittorio della Rocca and assisted by Giorgio Braghin.
The assembly masters and the first series of prototypes will be managed respectively by Dr. Tiziano Novo, and Gigi Gallina together with Giorgio Gariglio.
At the end of 2002, Engineer Piero Grillo swapped with Engineer Diego Avesani, manager of the Fiat Technical Department in Turin, as the director of the "Fiat 178 platform".
In the summer of 2003 Giorgetto Giugiaro was a special guest at the OCA art museum in the city of Sao Paulo, together with the entire Fiasa \ Fiat management, suppliers and political authorities, they presented the new third series of the Palio family at a world premiere.
It became such success that after the San Paolo show held in October 2003, a commission of specialized journalists went on to award this latest new Fiat Palio series the prestigious "Car of the Year 2004 South America" award.
In October 2003, coinciding with the entry into production of the Type 178-3, Roberto Arpini passed on the baton of technical direction for Stola Engineering do Brasil to the engineer Pasquale Papaliia assisted by Salvatore Tuvè.
Arpini returned to the Stola technical office in Cinisello Balsamo to work on the Ferrari 599 GTB Type 141 project.
The Brazilian version of the Fiat Idea that went into production in 2005 at the Fiasa plant was a car engineered by Stola Engineering do Brasil.
The premise of this choice by Fiasa was that at the end of 2001 Stola s.p.a. had just delivered to the Technical Management of Fiat Auto, all the engineering work for the new small minivan called Idea for the European market.
It was Engineer Papalia who coordinated every activity between Belo Horizonte and Rivoli for over a year, reporting directly to Engineer Alexandre Serretti of Fiasa.
The difficulty of this project was that the production needs in terms of synergies and costs meant that the bodywork, the relative structures of the Fiat Idea in the European version would have to be assembled on the chassis of the Palio Tipo 178-3 which would also include the mechanics and dashboard.
The final development work began at the end of 2002 and went on until summer of 2004, carried out entirely at Stola Engineering do Brasil.
The young engineers of Stola s.p.a volunteered to transfer for 3 years from Rivoli / Cinisello Balsamo to Belo Horizonte and had the opportunity to live an extraordinary work and life experience.
A special team spirit was born between them, not only in work but also in a happy conviviality, sharing the residences, spending the weekends and local holidays together .
The exceptional "mineira" cuisine and the best known "churrasco brasileiro" with the very light Antarctica and Brahma beers, the energizing guarana for abstainers, suited occasion for numerous dinners with friends.
Brazil is also a country famous for the friendliness of girls, and some of the young designers even found love, going on to be married.
For the Stola Family, this six-year South American experience was undoubtedly the most complex undertaking in terms of human energy, technical intelligence and financial commitment.
Millions of sheet metal parts have been printed, hundreds of thousands of sub-assemblies welded and tens of thousands of raw car bodies delivered just in time.
A new plant of 100,000 square meters staffed with a workforce of 1,200 people divided into three shifts, all from a green field site,the numbers following the last expansion in 2001 tell of an industrial vision created by the stubborn will of Roberto Stola.
For the commitment to the limit of physical endurance on the part of the closest collaborators Carlo Alecci, Carlo Biassoni, Marco Goffi and Gottardo Bustreo, an immense thanks to them from the Stola family.
Thanks to the resident Superintendents Newton Garzon and Guido Maina for the extraordinary work done together, and to all managers Enrico Negri, Celio De Castro, Giuseppe Facchin, Arturo Vidal, Giancarlo Zago, Pauline Wooley and Marcus Pacheco.
Franco Stola was the last Superintendent of the Stola do Brasil to work "directly" for Roberto and Alfredo; a special thanks to him from the family to which he belongs.
A thought also goes to the men of the Fiat / Fiasa management who in these seven years were colleagues on the project, including Paolo Cantarella, Gianni Razelli, Luigi Sburlati, Jonas Carvalho, Piero Grillo, Gianni Coda, Tommaso Le Pera, Appio Aguiari, Ugo Delfino , Claudio Demaria, Diego Avesani and Alexandre Serretti.
Roberto Stola became aware of his illness as early as April 1999 during one of the usual monthly trips to Belo Horizonte accompanied that time by Carlo Alecci.
In spite of everything, aided by supportive care, his active commitment to this enterprise would never fail until the summer of 2002.
On 26 July 2004 the Stola family sold the shares of Stola s.p.a. which also include 100% of those of its own companies: Stola do Brasil, Tecnocars and Estival.
The buyers,“Global Industriale”, a group of Italian entrepreneurs operating in the automotive sector.