IVECO Madrid builds trucks differently

At the heart of IVECO’s industrial operations is its Madrid facility, the only manufacturing site in Spain dedicated to heavy-duty industrial vehicles

The plant produces the company’s complete heavy truck range for international markets including Italy, Germany, Spain and Turkey.

Covering 374,000 m², the facility is built around a one-kilometre main assembly line and is capable of delivering close to 40,000 different vehicle configurations. With 267 core models and more than 2,800 customization options available, production is designed around highly specific customer demands. On average, the same truck configuration is assembled just three times annually.

“Every truck we build is essentially a one-off, custom-made to meet specific requirements,” commented José Manuel Jaquotot, director of IVECO’s Madrid and Valladolid plants.

“Each vehicle has a unique identifier that allows us to track it from cab production in Valladolid to final assembly in Madrid, ensuring full traceability and quality.”

Manufacturing operations at the Madrid site rely on a flexible and tightly coordinated production system supported by automation and intelligent logistics. Automated Guided Vehicles (AGVs) transport units across the line, enabling takt times to shift according to the complexity of each build while maintaining uninterrupted workflow across the plant.

Truck cabs arrive from the IVECO Valladolid Plant already painted and welded before being fully equipped in Madrid with dashboards, seats, bunks and airbags. The dashboard assembly process alone includes more than 100 electrical checks and is managed on a separate production line because of its technical complexity.

A major milestone in the process is the integration of the chassis and cab, commonly referred to as the “marriage” stage. Once combined, the vehicle progresses through the fitting of exterior parts, wheel installation and a series of final inspections. These include leak detection, geometry calibration and full functional testing before completion.

The site’s workforce remains central to its operational success. More than 2,700 employees support production activities, bringing the expertise and adaptability required to manage constant product evolution. During 2025, the plant successfully introduced ten new launches.

Sustainability also plays a defining role across operations. The Madrid facility operates entirely on renewable electricity and, in 2025, recycled almost 90% of the water used throughout production processes. Alongside the Valladolid plant, the site forms part of Iveco Group’s broader sustainability strategy and participates in a solar self-consumption initiative with Edison Next Spain, a project expected to help prevent around 500 tons of CO₂ emissions every year.

IVECO’s focus on decarbonisation extends beyond the vehicles themselves to the manufacturing ecosystem behind them. The Madrid plant reflects this broader ambition by combining advanced production technologies, large-scale customisation and sustainable industrial practices in one integrated operation.