In the automotive world, precision is not an optional extra but the very heart of every component. Vaccari & Bosi, a leading manufacturer of high-performance chassis for the world’s most prestigious supercars, has chosen Nexeeva as its strategic partner to implement a structured, robust and continuous digital management system across its various business areas, with the aim of ensuring excellence and operational continuity in production and quality control.
Who are Vaccari & Bosi?
Founded in 1953 by William Vaccari, the company began as a small mechanical workshop in Modena and grew rapidly, becoming an official supplier to Ferrari as early as 1956.
Today, it is a leading industrial player in the automotive sector, specialising in the development and production of chassis and complex components for the most prestigious manufacturers of sports and luxury cars. A true example of manufacturing excellence, combining the craftsmanship of ‘old-school’ artisans with advanced industrial processes.
A ‘quiet’ protagonist, as its LinkedIn profile describes it, because the company has always worked for famous and renowned automotive brands but has never boasted about it, preferring to work ‘behind the scenes’.
The problem: the challenge of production complexity
Growing means facing new challenges.
The increase in orders and the complexity of processes have given rise to new requirements within the company, such as the need to monitor production in real time via intuitive dashboards and to track order progress and machine status.
Furthermore, to prevent the large volume of data from leading to a lack of focus and fragmentation, it became necessary to implement structured analytical tools to enable rapid decision-making, as well as a system for monitoring quality defects in critical components.
The solution: IT management and IT monitoring
A technological infrastructure capable of keeping pace with the automotive industry, delivered through an IT management and monitoring service that combines strategic consultancy with technical operations.
Nexeeva has become an integral part of Vaccari & Bosi’s organisational fabric, acting as a genuine external yet on-site IT department.
Ongoing support: on-site IT management
An IT manager is on site three days a week to oversee the management, implementation and maintenance of the entire IT infrastructure.
A true “digital conductor” who understands the dynamics of the production departments and ensures that every computer or connected machine runs smoothly, intervening immediately in the event of critical issues to protect the company’s know-how from external threats and ensure that every system is always up to date and performing at its best.
The IT specialist is also responsible for monitoring and coordinating all information technology projects.
Photo: Image by Stefan Schweihofer from Pixabay
Network and server management: business continuity and data security
For an automotive company, the network and servers are the factory’s nervous system. If the network goes down, the production line comes to a halt, and in the automotive industry, every minute of downtime can cost thousands of euros.
Through our network, server and virtualisation management service, the company can rely on a secure, fast and always-on digital infrastructure:
– servers equipped with the most widely used and reliable virtualisation systems
– operating systems that are continuously updated.
Business continuity is ensured through hyperconvergence, and data security is guaranteed by high-end firewalls and switches. Furthermore
, both cold and hot backups play a key role in data recovery.
The network has been significantly improved in terms of reliability, performance and security.
Photo: Image by Bethany Drouin from Pixabay
“At Nexeeva, we found a high level of professionalism and expertise, which has enabled us over time to build and maintain state-of-the-art systems.”
Federico Ugolini (Vaccari&Bosi;)
IT Manager
Containerisation: the agility that speeds up production
The business software that manages production data has been placed within secure “containers”, which run on the company’s virtual machines.
This means that if the company were to change servers or expand, it would simply be a matter of “moving the containers” without having to reinstall everything from scratch, ensuring that production never stops.
The result is a well-organised system that is very easy to update and very difficult to crash.
Photo: Image by Reto Scheiwiller from Pixabay
Design and development of production and forecast dashboards
The design of intuitive production dashboards (digital control panels) and forecasting systems transforms the flow of business data into a digital ‘control tower’ that is easy to consult and provides immediate answers. In this way, management can monitor the data required for production line planning in real time, gaining an overview and enabling them to make strategic decisions based on hard facts, just like a driver monitoring the dashboard of their car on the track.
The dashboards were built using Grafana and Pentaho
Dashboards and Data Analysis
Delays in the delivery of finished products to customers
Dashboard dedicated to monitoring customer deliveries: displays overdue items, weekly coverage status (covered, not covered, partially covered), the percentage of items ready for delivery, and details by customer/item/chassis; it enables you to immediately identify delivery issues and take proactive action.
Order Deadlines – Machine Monitoring
View the status of machines in relation to order deadlines, including remaining hours and operational status (in progress, set-up, on hold, maintenance, available).
An operational tool for production rescheduling and priority management.
Production Metrics – Department CN7
Department dashboard showing machine status, quantity produced, quantity to be produced, scrap, and order completion percentage.
It provides a real-time overview of capacity utilisation and production performance.
PO Forecast – Materials Summary
Material requirements forecasting dashboard showing monthly coverage and colour-coded alerts for critical issues (green, yellow, red). Supports procurement planning and helps prevent production stoppages.
ETL and data flow orchestration
Data Exchange Job – Orders and Stock
The main ETL job that handles the automatic import of data from external systems (purchase orders, sales orders, forecasts, production orders, stock levels, BOMs and machine orders).
It includes checks on the update date, management of sequential data flows and updates to the import status, with email notifications in the event of an error.
It is the heart of the data integration process that feeds the production and forecasting dashboards.
WIP (Work In Progress) Management Job
A job dedicated to managing and recalculating WIP.
It processes orders, stock levels, scrap, commitments, materials, equipment, item coefficients, processing times and frame scheduling.
It progressively updates the status of orders and ensures consistency between actual production progress and the analytical data used in dashboards.
Job Status Update: Imports and Checks
An orchestration and control job that checks operational conditions (e.g. update day), manages import flows and updates process statuses. It includes error handling and the sending of automatic notifications to ensure traceability and operational continuity.
Pentaho jobs form the data backbone of the entire system, ensuring the integration, cleansing and consistency of the information on which the decision-making dashboards are based.
Development of custom modules on NexOne for specific workflows (e.g. quality control)
In a high-precision sector such as the automotive industry, where even a millimetre’s deviation can compromise an entire batch, quality management is not merely a duty but an essential pillar of competitiveness. Using the NexOne management and automation software, every batch is tracked in real time, cross-referencing data collected during sampling and production with information from the company’s ERP system.
For a company like Vaccari&Bosi, this translates into total control: from recording physical parameters on machinery to the immediate management of non-conformities. NexOne automates monitoring, drastically reducing the risk of human error and ensuring full compliance with the required international standards.
This means preventing rejects, optimising costs and guaranteeing a flawless end product.
NexOne – Quality Control Module (Specific Sampling)
A custom module developed for the digital management of quality control checks on critical components (e.g. welds).
It allows users to define inspection stages, technical specifications, tolerances (min/max/nominal), measuring instruments and operational notes.
It includes the ability to upload technical drawings and link inspection points directly to specific areas of the component.
It fully digitises the quality process, ensuring traceability, a complete audit trail and a reduction in manual errors.
NexOne – Integration of Technical Drawings and Control Points
An interface that links the technical drawing of the component to quality control points (e.g. R30A/B, R31A, etc.).
It allows operators to view critical areas graphically and record inspections in a guided manner.
It improves the accuracy of inspections on welds and structural components, increasing consistency and compliance with the standards required by the end customer.
NexOne represents the vertical application layer of the project, transforming paper-based operational procedures into structured and traceable digital workflows. Specifically, it was used to integrate a quality control workflow (which was manual/Excel-based)
Monitoring and vulnerability management
In an interconnected ecosystem such as the automotive sector, every computer, sensor or piece of machinery on the network is a potential entry point for external threats. Nexeeva’s security monitoring
and vulnerability management service acts as a digital sentinel within the company, working round the clock to prevent any disruption: it analyses data traffic in real time to detect suspicious anomalies and constantly scans systems for ‘weak points’ (software vulnerabilities or incorrect configurations).
Technologies used: Containers on virtual machines, Greenbone, LibreNMS.
Containers on virtual machines
Container Architecture – NexOne Ecosystem
Overview of the Docker environment hosting the NexOne microservices.
The architecture consists of separate APIs (production, machine, warehouse, quality, master, settings, account, document, gateway, etc.), dedicated databases (MariaDB, SQL Server), Redis caches and support services.
Each application module is containerised and isolated, ensuring scalability, simplified maintenance and separation of environments.
This structure allows for targeted updates without impacting the entire system.
Container Architecture – Stack Data & Monitoring
Overview of the containers used for data management and monitoring
:- The infrastructure is not merely an application, but an integrated and monitored ecosystem, designed to ensure reliability and security
.- The entire system is designed using a containerised microservices architecture, which enables modularity, resilience and total control over the infrastructure.
Greenbone (vulnerability management)
Greenbone – Operating System Vulnerability Report
Scan report showing the operating systems detected on the network (Linux/Unix, Windows, Windows Server, Ubuntu, WatchGuard Firewall) along with the average severity of the vulnerabilities identified.
It allows you to quickly identify which platforms are most at risk and on how many hosts critical vulnerabilities are present.
Greenbone – Historical Report and Severity Classification
An aggregated view of scan reports, categorised by severity (High, Medium, Low) and CVSS score.
This enables continuous monitoring of risk levels, tracking of scans performed, and monitoring of how vulnerabilities evolve over time.
Greenbone – Infrastructure Security Dashboard
A summary dashboard showing the distribution of vulnerabilities by severity level and the trend in CVEs over time.
It provides a strategic overview of the infrastructure’s security status, supporting remediation activities and cyber risk governance. The vulnerability management system ensures continuous monitoring, proactive identification of critical issues and structured control of cyber risk.
LibreNMS (network monitoring)
LibreNMS – Network Device Inventory and Monitoring
A detailed view of monitored network devices (Cisco switches, Mikrotik routers, WatchGuard firewalls, etc.), including operating system, uptime, metrics and operational status.
This allows you to keep the entire network infrastructure under control, checking device availability, firmware versions and stability.
LibreNMS – Overview Dashboard and Infrastructure Maps
Summary dashboard featuring:
– Top interfaces by traffic –
Top devices
– Host status (up/down)
– Active alerts
– Geographical and site-plan map of the infrastructure
– Enables real-time monitoring of the corporate network and immediate identification of anomalies or critical issues. The network monitoring system ensures operational continuity, complete visibility of equipment and proactive intervention in the event of anomalies
.- Check MK (infrastructure monitoring)
– Centralised logging-
Server and equipment
backups All managed on their servers.
Conclusions: a more agile and secure business
Nexeeva’s intervention introduced new software and eliminated the ‘blind spots’ that were holding back Vaccari & Bosi’s growth:
- Overview and control: managing a large number of product codes made it difficult to get a clear picture. Customised dashboards solved this problem, enabling us to turn data into quick decisions and improve on-time delivery.
- Reliability and continuity: the implementation of hyper-converged systems and the use of high-end firewalls and switches have ensured total operational continuity.
Today, network infrastructure and servers are no longer a cause for concern, but a guarantee of business continuity, supported by hyper-converged systems and high-end security.
In a strategic sector such as the automotive industry, where precision is essential, Vaccari & Bosi can continue to be the ‘silent protagonist’ of Motor Valley, knowing that it has a solid, secure digital engine behind it, ready for the challenges of Artificial Intelligence.
“If we had to sum up this journey in a single word, it would be ‘Reliability’.”
Daniela Biolchini (Vaccari&Bosi)
Head of Programming
Do you want to improve your company’s performance?
Find out how Nexeeva’s bespoke solutions can transform your business.