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CHRYSLER

World Class Manufacturing

Il percorso verso l'eccellenza

Luciano Massone
Range di prodotti
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Principi WCM
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1. La Sicurezza a livello World Class il fondamento di


Performance a livello World Class

2. I leader del WCM hanno una passione per gli standard

3. In una Azienda World Class la voce del cliente pu essere


udita nello stabilimento

4. Il WCM non accetta perdite di alcun tipo (l'obiettivo


sempre Zero: incidenti, difetti di qualit e di servizio, scorte,
guasti)

5. Un' applicazione rigorosa dei metodi WCM garantisce


l'eliminazione delle perdite

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Principi WCM
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6. In uno stabilimento World Class tutte le anomalie sono


immediatamente visibili (Polvere e fonti di contaminazione,
schemi di controllo, ... )

7. Il WCM si realizza nel posto di lavoro, non in ufficio

8. Il WCM si impara mettendo in pratica le tecniche con i team di


stabilimento

9. La forza del WCM deriva dal coinvolgimento delle persone

10. Le Aziende World Class sfruttano l'energia di una crisi per


ottenere un successo continuo

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Struttura WCM
rm
n&,..u t CHRYSLER

WC'M Slructure

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Struttura WCM
rmn&,..u t CHRYSLER

10 Pilastri Tecnici in un approccio a 7 steps


- -

Early
Logistics &
Professional Quality Equipment- People
Customer
Maintenance Control Product Development
Servi ce
Management

10 Pilastri Manageriali

Commitment
Level of
of
Expans1on
Organization

Sistema di Audit

Pilastri : 0-5 punti ~nze 50-59


punti
Gol d 70-84
punti

Silver 60-69 world 85 -100


Plant : 0-100 punti punti C1ass punti

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1O Pilastri tecnici in 7 steps
f CHRYSLER

People
Development

tf l o

Preventive Reactive

Reactiv

Proactive
Proactive

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WCM Focus
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Tutti i dipendenti

Sprechi e Perdite

Standard e Metodi

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Approccio
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STABILIMENTO

AREE DI ESPANSIONE

AREA MODELLO

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Risultati WCM
Safety rm1 CHRYSLER

Tychy Plant Fiat Group safety


(Frequency lndex 2006 vs 201 O)
(FGA)

-44/o
lnjuries -70/o
(2006 vs 2009)

Near misses
Best sector in the Group
-53/o reduction in
Unsafe acts & Conditions frequency index

r~ 1 n ~ , QQQ preventive ~~i n

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Focused improvement
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5 Perch Diagramma a radar


Brainstorming Phenomenon Why(1) Why(2) Why(3) Why(4)

Diagramma di Pareto Ciclo automanutenzione

4M analisi

SWe lH

t WHAT t WHO
.,,H.tt.ilhn[tlrodlcllidyouswtt-. probl&m -tfsth!l ~emrBlat~dro slol?

t WHICH
'MichFend(~Em)IUyou5eib1&

""""'
WHERE HOW
<+ ~4dyouS*ltteprOOiem? -tHow 1S Il stat& cNrl9&d lrOm opMut?

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Focused improvement
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Radar chart ltems


No METHODSfTOOLS/
DESCRIPTION PILLAR GROUP
APPROACH

5G break down, working abnormality , etc.) x x x


Good for simple sporadic and chronic loss
Used to clearly define the problem . (What, When , Where, Who,
2 5W1H Which , and How) x x x x

3 5 Why x x x x
yzes
4 4M problem and its x x
basic families.
Find out important
5 1)Prioritization , x x x x
Tools
2) Systematic , logical and 7WCM
detailed deployment of Tools
objecti~.es into right means
6 and right solutions , and x x x
measurement of the results
against the objecti~.es and
targets
l
7 x x x x x x x
Tools
Grasp the current situations 7WCM
4) 5W + 1H (2H) with the
8
5G principles
Two tools used to clearly identify the problem and see the x x x x x x Tools
ic al res ults of the m.
A method of analysis t o identify the true cause's) of the problem. 7WCM
9 5)Root-cause analysis x x x x x x
Tools

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Focused improvement
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Radar eh art ltems


METHODS/TOOLS/
DESCRIPTION PILLAR GROUP
APPROACH

Value Analysis/Engineering is a systematic and organized


23 VAlVE procedura! decision-making process. lt has been used in almost CD
ki nd of a n. l t hel
7NEW QC
44 Affinity diag rams Tools

50 ANOVA

Simple
51 Correlation analysis analytical
hniques

58 DOE (Design of

59 TAGUC HI Methods x

PPA ( Process Point


92
Analysis )
x

EPM;
130 DFMEA -DES IGN FMEA
QC

159 Theory of Constraints

Binomia! probability paper Fl


220

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Workplace Organization
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l Prima l l Dopo l
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Workplace Organization
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lPrima l l Dopo l
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Workplace Organization
rm
... _ .. _ , CHRYSLER

lPrima l l Dopo l
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Workplace Organization
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Workplace Organization
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Workplace Organization
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Workplace Organization
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Workplace Organization
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Workplace Organization
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PROBLEM P~OBLEM PHENOMENA SOLUTION

PROBLEM PHENOMENA SOWTION PROBLEM PHENOME,N A

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Workplace Organization e Logistics
CHRYSLER

lPrima l l Dopo l
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Workplace Organization e Logistics
CHRYSLER

i PRIMA i i DOPO i
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Workplace Organization
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LOSSES LOSSES 100%


Technical
efflclency
Waste/Rewor1<
Une Balanclng

-30/o
NVAA
NVAA ( * )

Golden zone & one-piece


flow application
l
Machine

Riorganizzazione del posto di lavoro per


ridurre la movimentazione non necessaria e
aumentare la produttivit NVAA reduction
(*) NVAA : Not Value Added Activities; (**) VAA: Value Added Activities

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Logistics: materiali sequenziati
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Evoluzione del JUST IN SEQUENCE

lo GENERAZIONE 2 GENERAZIONE 3 GENERAZIONE

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Logistics
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Transportation of materials
Fork Lifts to the line side, one part
number at a time

Tuggers

Sequenced Materia!

Automated
AGV transporting the
guided veh icle car kits to the line side

v
Kitting transportation

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Logistics
rm CHRYSLER

Transportation & Handling

Logistics Cost
FGA European plants

Re-engineering del processo di


handling sulla base degli
-34/o
Standards sviluppati Automatic Guided 2010 vs 2006
Vehicles

Contenitori abbattibili per migliorare il coefficente di


utilizzo del trasporto

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Professional maintenance
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Raccolta dati macchina e analisi Analisi e Contromisure

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Professional maintenance
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MANUTENZIONE PREVENTIVA
ANDAMENTO GUASTI
Preventive Schedule
SUGGESTED
85 CHECKS BY THE
MANUFACTURER ;

CHECKS
24 RESULTING FROM
BREAKDOWNS
ANALYSIS

CHECKS FROM
12 EXPERIENCE IN Q O/o
SIMILAR
EQUIPMENT;

PRIMA DOPO
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Professional maintenance
rm CHRYSLER

PRIMA DOPO

MODIFICA
CONDIZIONI
DELL'IMPIANTO IMPIANTO
NASCOSTE PER SEMPLICITA'
DI ISPEZIONE

IMPIANTO RIPRISTINATO ALLE CONDIZIONI DI BASE

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Quality
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Quality gates

Prompt feedback

Cou nter-measu res


b Il CO'\! lXI~ .I&.O C t TI.MO$ ~~~,-. -

80/o riduzione dei costi


di garanzia dal 2006 al
2009

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Quality
CHRYSLER

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Quality
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4M analysis

Machine Material

CaJibratioo
Eov.irOQITieOt

A ccuracy Operator

Bias Recipe

Measurement Method

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Environment
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Energy Reduction

Electrical energy
Eiectric motors controlled by inverter
Substitution of old motors

WCM contribuisce al
Compressed air
piano di sostenibilit in
Leakage reduction
Pressure optimization
maniera importante

21 /o di riduzione
Heating - Cooling nell'utilizzo delle energie
lnsulation dal 2006 al 2010
Heat recovery from exhaust gas
(GJ/vehicle)

Green energy 23/o di riduzione di co2


Purchase of green-certified electrical dal 2008 to 2010
energy
Photovoltaic generation (tons/vehicle)
Use of other green energy sources such as
landfill gas

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People Development
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Collection & evaluation


Targets
Weekly evaluation
Feedback
Risultati

Manufacturing training system


Quality Gates
. -it~
,. . ;- .. .
l milione di suggerimenti
Focused training
.._ -
( 4x 2006 leve l)
Suggestions generated
10 proposte/persona
all'anno (15 nei migliori
Team conventions
plant)
Periodic workshops
Focused discussion Assenteismo ridotto del
Suggestions generated 14/o vs. 2006

Recognition & rewarding


Plant Manager review
Best proposals
Best benefit/cost ratio reward

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Melfi Campus
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World Class Modeling

World Class Quality

World Class Assembly

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Knowledge Management
Dalle best Practice agli standards rm CHRYSLER

,
/ '
l
l '
l
l
~ ........
""

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WCM lntegration
CHRYSLER

More than 4,800


Members

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WPI - Work Piace lntegration
rm CHRYSLER

The best of Fiat

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WCM Development Center
Sviluppo delle risorse umane strategiche rm CHRYSLER

People
development
for Plants

New Leaders
development

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Espansione
World Class Approach rm CHRYSLER

... espansione ai fornitori (WCM Suppliers)


Supplier
Program
Tier2
WCM
Development
.. Center
..

Come?
--.,..,_\
----------~~-- - - - - - - - ~ r
// t<::.... World Class Supplier
i ~~-- ------------c> l ~.:=.:;: / ' . . Program
!_,,',, ~n _____: :. _ l\ .. '\;~=;:::.:JG . .fr
IJ/ J _/ r?J'. \. \ /
Fiat Plants \.

-~A-----~~~~-- - ~\ . ,_ :~-::'::////
Applicare/Allineare la
Metodologia World Class
ai sistemi di produzione dei
~--/- '

fornitori
------4 o:; \
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WCM Suppliers
rm CHRYSLER

Specific Supplier Program and Alignment of


Production System for ali new contracts

tv60/o APV
Praductian System
Alignment Agreement
far ali new saurcings

2006 2009 2014 E


} tv2QO/o APV
WCM Pragram far Specific
Supplier Plants

Support FIAT Group Plants

Supplier Plants
550

-J rv 60/o
3
2006 2009 2014E
/ ~ear toFiat
Group plants

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WCM Chrysler
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May 16th 2009: WCM kick-off


CHRVSL R

WCM launched in 30 plants in


USA, Canada, Mexico
Cast perimeter 2010: $3.2bn
Full UAW & CAW commitment

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New Standards
rm CHRYSLER

l
.ICS

li
Fte le f ~ , ec i g lay ut

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Elementi chiave
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World Class Operations


bisogni:
Leadership
ools Roadmap
Tools
e ...

Sistema di Audit
per verificare
leadership
chiarezza della rotta
uso rigoroso dei tools

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rm1
....... _ .. _, CHRYSLER

Grazie

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