Astolfi 1963: Implementing Triangular Kanban for a Streamlined Supply Chain

Astolfi 1963 is an Italian company with a longstanding tradition in producing high-quality mattresses and bedding systems. Founded by grandfather Pietro and carried on by his son Moreno and grandson Omar, the company has always focused on craftsmanship and attention to detail.

With a cross-functional team of designers, carpenters, tailors, and artisans, Astolfi ensures excellence in every stage of product development and manufacturing.

Recently, Astolfi joined the Tomasella network, a major player in the furniture sector, consolidating its market position and unlocking new growth opportunities.

In 2021, Astolfi began a lean and digital transformation journey aimed at reducing waste and improving operational efficiency. Among the key initiatives was adopting KanbanRocket, a supply chain management software for lean material flow control in purchasing, production, and logistics.

In 2022, Astolfi selected TALARYS as a technology partner to implement an e-kanban system integrating suppliers and subcontractors while optimizing inventory management.

Types of Kanban Implemented

Four types of Kanban were deployed, each tailored to specific internal or external flows:

• Procurement Kanban: 11 strategic suppliers were trained and involved to manage raw material replenishment. After a pilot test, Kanban was extended to all items. Suppliers now use KanbanRocket to monitor stock status and plan deliveries proactively.
• Production Kanban: Used for managing internal semi-finished production, improving workflow and reducing waiting times.
• Subcontractor Kanban: Coordinates production with specialized third-party contractors. Astolfi pulls semi-finished goods rationally from subcontractors, avoiding overproduction.
• Triangular Kanban: A unique flow where subcontractors directly trigger material calls from Astolfi’s suppliers. Although Astolfi owns the material, it is shipped directly from supplier to subcontractor, preserving strategic purchasing relationships and reducing logistical delays.

Triangular Kanban in Practice

This system automates inventory handling at subcontractors, eliminating the need for materials to pass through Astolfi’s central warehouse. Orders are triggered in KanbanRocket and generated in Astolfi’s ERP, with delivery directly to the subcontractor.

All parties operate within the KanbanRocket platform in real time, with bidirectional ERP integration ensuring accurate administrative processes.

Six months after go-live, Astolfi reported:

• 72 days average lead time reduction
• On-time deliveries improved from 78% to 97.5%
• 33% inventory reduction for triangular Kanban items

Moreover, real-time collaboration through KanbanRocket drastically reduced low-value communications (emails, calls) between the parties.

Photos of KanbanRocket-managed supermarkets show organized, clean, and visually controlled environments, enabling a truly lean supply chain.

Astolfi 1963’s project proves that, when correctly sized and integrated, e-kanban can become a true engine of competitiveness—even in traditional manufacturing environments. With KanbanRocket, Astolfi is now more connected, agile, and ready to meet future market challenges.