WCM – WORLD CLASS MANUFACTURING

PROGRAM

20 Novembre, 2010
What is the World Class Manufacturing ?

WCM (World Class Manufacturing) is prepared for increasing the

shopfloor standards to a world class level with improvement and
development in a systematic way.

Focus Areas:
 S: Safety : to eliminate accident

 Q: Quality : to way to reach the best production quality in worldwide

 C: Cost : Reduce production cost by reducing waste and loss

 D: Delivery : Reduce delivery time

 E: Environment : Reduce environmental accidents to zero and reduce negative
environmental effects
WCM in Industry

WCM is a methodology used by many

companies of automotive and various
sectors worldwide:
• Fiat Group
• Chrysler
• Royal Mail
• Volvo
• Ariston Thermo Group
• Sistema Poland
• Tarkett
• Elica

List of the firms involved in WCM Award Ceremony held in London in

October 2010 .
WCM Program in Fiat World

The WCM studies are carried out in about 150 factories of Fiat
and Chrysler Group.

Factory
WCM Program in the Suppliers

Since 2008, the strategic suppliers of FIAT Group companies

have been integrated into the WCM Program.

WCM@S Program 2008 2009 2010 2011 2012 2013 2014

FIAT GROUP
3 16 60 170 350 475 565
(Worldwide)

TOFAŞ 2 7 10 23 28
WCM Basic Structure and Objectives

Safety
Workplace
Quality Organization
Maintenance Logistic
Cost
Deployment

Total Quality Total Total

Method & Just in Time
Control Industrial Eng. Productive Main.
Standards (JIT)
(TQC) (TIE) (TPM)

Quality Technical
Productivite Service Level
Focus Improving Efficiency

Target 0 Defect 0 Waste 0 Breakdown 0 Stock

0 Accident
World Class Manufacturing Approach

• What is the Problem?

• Where?
• What is the priority?

Waste/
Evaluation of Results Loss
Analysis

Improvement Right
and Expansion Methods

Benefit / Cost
Implementation

Implementation with Discipline

Participation of all employees

World Class Manufacturing Structure
TOFAŞ WCM Road Map

TOFAŞ, which has been selected as the the first ‘Silver Factory’
of FIAT Group in 2009 with a 62-point WCM audit score, is
trying to be the first ‘Golden Factory’ surpassing the 70-point in
this year.
TOFAŞ’s gains within 5-year WCM Journey

Improvement in Accident Frequencies 97 %

Reduction in Transformation Cost 35 %

Improvement in Hours per Vehicle 20 %

Improvement in Quality Indicators 62 %

Proposal per Person 38