Application of World Class Manufacturing to an automotive enterprise and integration with its quality management system

An Enterprise can present in every moment numerously issues and problems that have to be necessarily faced and solved in such a way that the objectives are respected. For this reason borns the requirement to create an opportune and valid method to reach this scope. This requirement culminates in the definition of activities provided by the World Class Manufacturing, namely a “way to think” well structured and defined that has as objective to achieve a continuous improvement of productive activity setting to zero the losses and wastes, with a solid base founded on the involvement of personnel, on choices and objectives shared at each level of hierarchical pyramid . In the second chapter of this thesis is therefore introduced the World Class Manufacturing, starting from the American origins in 90’s until its adoption and implementation in our country. So the principal features of the method are explained. In the third chapter is introduced in its complex the structure of the method, which is characterized by ten technical pillars and an equal number of managerial pillars. In each technical pillar the activities are articulated in a subdivision of seven steps that have to be followed in order to realize each one of objectives prefixed, with the detection of issues and problems that have to be faced, and therefore the resolving activities that must be applied, ending with an improvement of approaches and structures used. The fourth chapter consists in a short overview on the ATB S.p.a, on its history and structure, with particular attention to the Valperga plant, which is devoted to machining and assembly; here i spent part of my period of internship in the technical office, the “heart” of the plant. In particular, in the last paragraph of this chapter is discussed the route map of WCM of the enterprise. It allows understanding the changes occurred in the plant, clarifying what has done and what it is going to be done in order to obtain that improvement which is the goal of all methodology; therefore, it provides a vision of plant in the future and the direction followed to reach the fixed objectives. In the fifth chapter the attention is moved to The Forno Canavese plant, which is devoted to forging; here i spent the larger part of my internship for the accomplishment of the main project assigned to me. In this chapter are discussed the main aspects of the forging technology and the steps of production of the raw parts and dies. Eventually, in the last part are introduced the main technologies adopted in the plant for dies design, forging and quality control of the raw parts produced. Instead, the last chapter is focused on the main project entrusted to me during my experience in ATB, it was devoted to the reduction of the steel required for components production through the reduction of wastes due to the cut of the initial bars of steel. The activity was performed without affecting the standards of quality required by the clients, therefore, from this point of view it was actually a WCM activity.