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Work Place Integration

All automakers face the challenge of remaining profitable despite increasing competitiveness and a strict regulatory environment.

FCA addressed this challenge through the adoption of World Class Manufacturing (WCM), a methodology that focuses on eliminating loss and waste during the manufacturing process.

Further reductions in operational expenditure (OPEX) and capital expenditure (CAPEX) are achieved through Work Place Integration, which takes place during the Early Product Development phase.


What is WPI?


The Work Place Integration (WPI) process, which is implemented between Program Approval and Job 1, incorporates input from all levels of the manufacturing process to identify and address issues prior to the Verification of Process (VP) build. The process uses WCM tools to focus on eliminating waste and reducing Non-Value Added Activities (NVAA), and it is designed to facilitate a vertical launch.

 


Analysis of all WCM pillars during the design of individual workstations ensures that every aspect of safety, quality and productivity is taken into consideration from the very beginning.

A key element in the success of WPI is the direct involvement of Team Leaders from the plant in the process design phase.

 

Key Elements of WPI

  • Focus on the workstation
  • 360° integration: involvement of all stakeholders in the New Product Development process
  • Begins up to 2 years prior to start of production
  • High level of detail: Station Readiness approach, detailed WCM check-list
  • Availability of all tools and know-how

Design Review with KPI and KAI Boards


A three-level system of KPIs and KAIs is used to verify progress and ensure achievement of targets.

 
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