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 :
 Q: Quality :
 C: Cost :
to eliminate accident
to way to reach the best production quality in worldwide
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
FIAT GROUP
(Worldwide)
TOFAŞ
2008
2009
2010
2011
2012 2013
2014
3
16
60
170
350
475
565
2
7
10
23
28
WCM Basic Structure and Objectives
Safety
Quality
Workplace
Organization
Maintenance
Logistic
Total Quality
Control
(TQC)
Total
Industrial Eng.
(TIE)
Total
Productive Main.
(TPM)
Just in Time
(JIT)
Focus
Quality
Improving
Productivite
Technical
Efficiency
Service Level
Target
0 Defect
0 Waste
0 Breakdown
0 Stock
Cost
Deployment
Method &
Standards
0 Accident
World Class Manufacturing Approach
• What is the Problem?
• Where?
• What is the priority?
Evaluation of Results
Waste/
Loss
Analysis
Improvement
and Expansion
Right
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