PDCA CYCLE

Presented by –
Ankur Bhatt (80303190017)
Shreya Gupta (80303190051)
Deepanjan Datta (80303190034)
Samriddhi Khatri (80303190071)
Shambhawi Sinha (80303190130)
 WORLD CLASS MANUFACTURING

• World Class Manufacturing - manufacturing system defined by 6 International companies including Fiat
Group Automobiles
• It has the intent to raise their performances and standards to World Class level with the cooperation of
leading European and Japanese experts
• Includes all plant processes including quality, maintenance, cost management and logistics from a universal
point of view.
 COMPANY – FIAT GROUP AUTOMOBILES
 Automotive-focused industrial group engaged in designing, manufacturing and selling cars for the mass market

 BRANDS

• Mass Market brands - Fiat, Lancia, Alfa Romeo, Fiat Professional and Abarth

• Luxury cars brands - Ferrari and Maserati

 SECTORS

• Components sector - Magneti Marelli, Teksid and Fiat Power train

• Production systems sector – Comau

 Diversified business portfolio , thus it caters demand fluctuations.

 Headquarter - Turin, Italy

 No of employees - 137,801

 Revenue - € 59 billion
 PROBLEM STATEMENT

• Aim - To increase the flexibility and productivity in an Elementary Technology Unit of Mechanical
Subgroups in part of FGA’s assembling process in Cassino Plant through PDCA approach and WCM
methodology.
•• Cost
Cost analysis
analysis and
and •• Analysis
Analysis of
of
Losses
Losses Analysis
Analysis Non valued
Non valued
activities
activities
PLAN DO

ACT CHECK
•• Extension
Extension of
of •• Analysis
Analysis of
of
Methodology
Methodology and
and results
results and
and
other cases
other cases check
check of
of
losses
losses
reduction
reduction
 PLAN
• Cost Deployment -Data collection regarding NVAA
• Analyze the losses (MUDA analysis) –
 Non-value-added activities
 Low balancing levels

 Handling losses
 Delay in material procurement
 Defects
 Troubleshooting Machines
 Setup
 Breakdown

• Aim of Analysis - To identify a program allowing to generate savings policies based on Cost Deployment
• Quality tool – Pareto charts – to identify losses from Cost Deployment from the Assembly Shop
 DO
• Second step of PDCA
• Analysis of the NVAA
• Analysis of re-balancing line and work as per the analysis of the logistics flows using the material matrix and
the flows matrix
• Analysing prototypes to improve workstation ergonomics and ensuring minimum material handling
• Application of countermeasures developed in the production process and logistics handling stages.
• Using MUDA Analysis, Spaghetti Charts and Kaizen Standards to determine and reduce NVAA
 CHECK

• Third stage of PDCA

• Analysing the project's results against defined expectations to assess if the idea has worked
• Analysing results to ensure productivity improvement, ergonomic improvement and optimization in the
plant and external logistics flows
• Keeping losses in check as per the Cost Deployment
• Summary of the results:

- 75% improvement in productivity and direct labour

- 85% improvement in workplace ergonomics as per rest factors

- Optimization of logistic flows as per the flow metrics

 ACT

• After the model is analyzed in the “check” phase and the results are compared with the plans made.
• If the results are according to the “plan” phase and are positive then they are implemented and standardized
in the organization.
• However, if they do not match the requirements then opportunities for improvements and bottlenecks are
found to start a new cycle.
• Act phase includes decisions on how to implements the model, ways to implement, ways to make the change
acceptable, identification of areas of improvement, and ways to start a new cycle.
 CONCLUSION

The case study states the importance of World Class Manufacturing and how it allows to create a model
which initially identifies the losses, finds the cause of losses and bottlenecks and using various tools to reduce
the losses and improve the productivity and efficiency of the organization
There is greater efficiency due to reduction in NVAA, and better logistics system, the work is completed
within the allotted time without any wastage.
There is also greater flexibility because a lot of models can be tried and tested to find the best possible model.
There is also increased productivity since there is improved ergonomics and work is completed in a better and
optimised way.
THANK YOU