USA - The FCA US Warren Truck Assembly Plant has been awarded bronze status for its efforts in implementing World Class Manufacturing

• Michigan truck plant becomes 20th North American facility to achieve bronze in World Class Manufacturing methodology
• Nearly 14 million award-winning trucks have rolled off the line since 1938
• Award recognizes progress toward becoming World Class

The FCA US Warren Truck Assembly Plant has been awarded bronze status for its efforts in implementing World Class Manufacturing (WCM). It becomes the 20th North American facility to reach the milestone award and brings to seven the number of plants that have been designated bronze in 2016.

The 78-year-old suburban Detroit truck plant earned bronze after receiving a minimum of 50 points in 10 technical and 10 managerial pillars following a two-day independent audit held on Oct. 24 and 25. 

The plant demonstrated clear WCM know-how and competence through employee-conducted pillar presentations and a review of projects implemented across the shop floor. The designation recognizes the long-term commitment of a workforce to making significant changes that can secure the future of a facility.

“Reaching bronze is a significant achievement as it confirms the workforce’s understanding of the WCM methodology and its dedication to implementing best practices that will make our facilities the best in the world,” said Brian Harlow, Vice President – Manufacturing, FCA North America. “At Warren Truck and across our global manufacturing footprint, our employees now have the tools and resources to eliminate waste by improving processes, increasing productivity, and improving quality and safety, while at the same time putting dignity into the workplace.

“Our Warren Truck workforce is to be commended for embracing WCM as a way of life,” said Harlow. “Together with the support and involvement of our UAW partners, we 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 employees 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.

Currently, there are three North American plants at a silver status, having been elevated from bronze after receiving a minimum of 60 points during an audit. Silver is awarded to plants that have taken a preventative approach to implementing the WCM methodology throughout the facility. The silver plants are Windsor Assembly (Ont.) awarded in March 2014; Dundee Engine (Mich.) recognized in May 2015; and Toledo Assembly Complex (Ohio) designated in May 2016.

In addition to Warren Truck, the 16 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.)
• Mack Avenue Engine (Detroit)
• Toledo Machining (Ohio)