“The best-case scenario is to have people in the jobs, and the place is stable and predictable,” he said. Kavajecz said employment is stable, which is a key to running an efficient plant. Team leaders help solve issues, with eyes toward quality and safety. There’s also a team leader structure with a 1:6 ratio, meaning one team leader for every six team members. WCM is supported by 10 technical and 10 management pillars - it’s a model that focuses on making continuous improvements, Kavajecz said. Fiat Chrysler operates under its World Class Manufacturing model, which aims to eliminate loss and waste and promote efficiency. Robotic technology and workers coexist daily at the plant. Everybody’s got blue jumpsuits on and hairnets.” The paint shop is a very clean atmosphere: Due to the nature of painting, you have to have a lint-free environment. The body shop is all about welding and dimensional control. The stamping presses are producing metal parts. “It runs like a well-oiled machine, but there’s a lot of action and movement. “Most people when they come in the plant for the first time are shocked at the housekeeping: It’s a very neat, orderly, disciplined, clean shop,” Kavajecz noted. To the extreme west is the sequencing center. The body shop is on the north end, and the west end houses the paint shop on the second floor. Moving from right to left, the whole part of the building on the south side is the assembly shop. Staff stamps all major automobile body panels, fenders, doors, hoods and quarter panels. Looking at the plant from Interstate 90, the stamping plant is on the east end (right side). And the action runs from Monday morning until Sunday morning. Monday morning, work starts in the stamping department, body shop, paint shop, assembly shop, etc.
The typical week starts off with the maintenance crew working Sunday night to make sure everything is ready to run Monday morning. He said the plant is “rocking and rolling” 20 hours a day, six days a week with three crews: The “A” crew works Monday through Thursday “B” crew works Wednesday through Saturday and “C” crew works days Friday and Saturday and nights Monday and Tuesday.
to 4:30 p.m., and then the night shift works 6 p.m. That schedule was implemented in 2012.Įach crew works days and nights, or a combination thereof, Kavajecz explained. To produce those vehicles, the plant runs a 3-2-120 operating pattern, meaning three crews that work four 10-hour days on two shifts for 120 production hours per week.
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