WCM methodology support solution used in the Fiat group.

1. HSI Ideas for productivity
Fiat Powertrain Betim - Brazil WCM Solution
TrakSYS™ - Real-Time tool for WCM
by Alexandre Sujkowski (Solutions Manager - HSI, a Parsec Value Added Reseller) and Rodrigo Salustiano
Silva Miranda (Engines Process Engineering - Fiat Powertrain Technologies)
Fiat Group And WCM Methodology
WCM (World Class Manufacturing) methodology is being used by all Fiat Group companies that have
manufacturing production process. This methodology has been identified as key in efforts to achieve
sustainability and enhancing competitiveness.
Based on the most competitive aspects of the Toyota Production System and through benchmarking
production systems in Europe, the WCM focused Fiat Group on the main concepts of Total Industry
Engineer (TIE), Total Quality Control (TQC), Total Productive Maintenance (TPM) and Just in Time (JIT).
The WCM program as adopted in factories is achieving important results including typical performance
efficiency in equipment, reducing waste, increasing customer service level and also in the way of working in
the factory and ergonomic quality in workplaces. In addition this program boosts innovation, changes
through involvement, contribution and creativity from all.
WCM Pillars
The methodology implementation is developed based on 20 pillars - 10 technical and 10 managerial.
The Cost Deployment pillar (Costs), for example, systematically identifies factory waste and losses,
evaluating and transforming them into precise costs. This is achieved based on the waste relation of
resultant losses and root causes.
Figure 1 - WCM Pillars
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2. HSI Ideas for productivity
Fiat Powertrain Betim - Brazil WCM Solution
The root cause understanding of waste and losses makes it possible to have an accurate cost of
deployment and a guide to define the best technical method (AM, WO, TPM, QC) to eliminate the source of
the loss, and also helps to clearly evaluate the cost benefits relation between the efforts to eliminate the
loss and the expected performance improvement.
TrakSYS™ - Real-Time tool for WCM
The TrakSYS™ real-time manufacturing operations and performance management solution has a complete
set of tools that enable real-time management of manufacturing environments. The TrakSYS solution,
aligned with the concepts of WCM methodology, has been used as an important tool to support WCM at
Fiat Powertrain plants in Brazil.
The solution is responsible for collecting production and equipment data from PLC networks in realtime,
evaluating and storing this data based on a configurable and flexible business rules model and
contextualizing them in real-time reports, dashboards and cost views.
TrakSYS provides detailed information for various teams in the plants in real-time, such as: location of the
loss, identification of the loss, and cost of losses.
Figure 2 - Visual Management and Cost of Losses Identification Example
For more information about the solution feel free to contact:
Alexandre Sujkowski - asujkowski@hsinet.com.br (Solutions Manager at HSI - Parsec VAR South America) or
Rodrigo Salustiano Silva Miranda - rodrigo.miranda@fiat.com.br (Engines Process Engineering – Fiat
Industrial Motores LATAM - Betim Plant - Brazil)
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hsinet.com.br 55(11) 4468-6868