The FCA US Mack Avenue Engine and Toledo Machining Plants have been awarded bronze status for their efforts in implementing World Class Manufacturing (WCM). They become the 18th and 19th North American facilities to reach the milestone award and bring to six the number of plants that have been designated bronze in 2016.
In reaching bronze status, the Detroit-based engine plant and suburban Toledo component plant earned a minimum of 50 points in 10 technical and 10 managerial pillars following two-day independent audits held during the week of Sept. 19. Through employee-conducted pillar presentations and a review of projects implemented across the shop floor, the plants demonstrated clear WCM know-how and competence. The designation recognizes the long-term dedication of the workforce to making significant changes that can secure the future of a facility.
“The road to bronze for both of these facilities has had its challenges, but their tireless effort and resilient commitment to WCM has now been recognized and duly rewarded,” said Brian Harlow, Vice President – Manufacturing, FCA North America. “Using the WCM methodology, our employees are suggesting process improvements to help eliminate waste, increase productivity and improve quality and safety, which are ultimately making our facilities more efficient.
“The involvement of our UAW partners in the implementation of WCM has been critical to the success we have achieved since 2009,” said Harlow. “Their continued commitment will ensure that the Company meets its long-term business goals and provides a secure future for all employees.”
WCM, first implemented by Fiat in 2006 and introduced to Chrysler Group as part of the alliance between the two companies in June 2009, is a methodology that engages the workforce to provide and implement suggestions on how to improve their jobs and their plants, promoting a strong sense of ownership. Plants awarded for their efforts also have a role in accelerating the implementation of WCM throughout the organization as coaches and mentors.
During an audit, zero to five points are awarded for each of the 10 technical pillars, which include safety, workplace organization, logistics and the environment, and for each of the 10 managerial pillars, such as management commitment, clarity of objectives, allocation of people, motivation of operators and commitment of the organization. A score of 85 would indicate World Class.
Of the 19 plants that have achieved bronze, three have gone on to be awarded silver – Windsor Assembly Plant (Ont.) in March 2014, Dundee Engine Plant (Mich.) in May 2015 and Toledo Assembly Complex in May 2016. In addition to Mack Avenue and Toledo Machining, the 14 other facilities that currently hold the WCM bronze designation are:
- Saltillo Truck Assembly Plant (Mexico)
- Saltillo South Engine Plant (Mexico)
- Trenton Engine Complex (Mich.)
- Warren Stamping Plant (Mich.)
- Indiana Transmission Plant II (Kokomo, Ind.)
- Kokomo Transmission Plant (Ind.)
- Kokomo Casting Plant (Ind.)
- Toluca Assembly Plant (Mexico)
- Sterling Stamping Plant (Sterling Heights, Mich.)
- Brampton Assembly Plant (Ontario, Canada)
- Tipton Transmission Plant (Ind.)
- Belvidere Assembly Plant (Ill.)
- Saltillo Van (Mexico)
- Indiana Transmission Plant I (Kokomo, Ind.)
