The FCA US Mack Avenue Engine Plant is celebrating after being honored with a silver award in the company’s World Class Manufacturing (WCM) methodology. The Detroit plant, which produces the award-winning Pentastar engine family, has been recognized for its efforts in expanding WCM throughout the facility, an honor it achieved in record time.
Only 15 months after being awarded the bronze award, Mack Avenue Engine earned the milestone award following a two-day audit during which it earned a minimum of 60 points in 10 technical and 10 managerial pillars by demonstrating clear WCM know-how and competence through employee-conducted pillar presentations and a review of projects that have been expanded across the shop floor.
Mack Avenue’s award brings the total number of FCA North American facilities that have been designated silver plants to five. The other four are Windsor Assembly Plant (Ontario), Dundee Engine Plant (Michigan), Toledo Assembly (Ohio) and Saltillo South Engine (Mexico). Windsor Assembly was the first North American plant to reach silver status, an honor it received in March 2014.
“The Mack Avenue employees are to be applauded for their commitment to and focus on continuous improvement, which has resulted in being designated a silver plant in record time, an unprecedented achievement,” said Brian Harlow, vice president – manufacturing, FCA North America. “They have truly embraced WCM and demonstrated the proper competencies, rigor and pace that make them deserving of this designation. Their deeper understanding of the methodology and tireless efforts to expand its implementation make them a valuable resource for other plants within the FCA network.”
The achievement of WCM award levels, as confirmed through independent audits, recognizes the long-term commitment of the workforce to making significant changes that can secure the future of a facility. Awarded plants also have a role in accelerating the implementation of WCM throughout the organization as coaches and mentors.
WCM was first implemented by Fiat in 2006 and introduced to Chrysler Group as part of the alliance between the two companies in June 2009. It is a methodology that focuses on eliminating waste, increasing productivity and improving quality and safety in a systematic and organized way. WCM engages the workforce to provide and implement suggestions on how to improve their jobs and their plants, promoting a sense of ownership.
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 80 would indicate World Class.
In addition to the five silver plants, there are currently 15 facilities that hold the WCM bronze designation:
- Saltillo Truck Assembly (Mexico)
- Trenton Engine Complex (Michigan)
- Indiana Transmission Plant II (Kokomo, Indiana)
- Kokomo Transmission Plant (Indiana)
- Kokomo Casting (Indiana)
- Toluca Assembly (Mexico)
- Sterling Stamping (Sterling Heights, Michigan)
- Brampton Assembly (Ontario, Canada)
- Belvidere Assembly Plant (Illinois)
- Warren Stamping (Michigan)
- Saltillo Van (Mexico)
- Indiana Transmission Plant I (Kokomo, Indiana)
- Toledo Machining (Ohio)
- Warren Truck (Warren, Michigan)
- Tipton Transmission (Tipton, Indiana)