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FIAT AUTOMOBILES FCA 4.0: smart manufacturing for smart product

obility is now at the centre of a Technology (ICT) infrastructure, developed with highly disruptive technological different technological partners, known as the revolution. Today, the ability to New Plant Landscape (NPL) has already been compete is the domain of those deployed at major FCA plants worldwide. NPL Mwho are capable in the short and medium-term employs advanced ICT solutions to help achieve not just of reinventing their products to address high standards of quality in manufacturing and new customer experience paradigms, but also assembly processes through rapid decision- of conceiving new ways of producing them. making at all levels of the value chain. Automakers need to innovate in ways that The increased digitalisation of FCA plant are both revolutionary and responsible. Being workstations reinforces the concept that revolutionary means further accelerating the collaboration between humans and technology innovation process by opening it up to new can unlock opportunities in terms of efficiencies, contributors and agents of change such as ergonomics, quality and the empowerment of employees, customers and external partners. employees. At the same time, that process must be For more than 10 years, FCA has leveraged responsible, guided by the concept of a circular these opportunities through the implementation economy where flexible manufacturing systems of World Class Manufacturing (WCM) at allow a more intelligent use of materials, FCA plants worldwide. WCM represents the resources can be tracked and re-used, rather foundation of this progressive transition to a than just consumed. smart modular factory model. It provides FCA- FCA is already creating the right conditions specific language for deployment of the i4.0 and environment for this new era of innovation, concepts of lean, smart and digital production. digitalisation and automation. The formula The need for flexible manufacturing is for the future is called industry 4.0 (i4.0), and addressed within the i4.0 approach through FCA is already there with its company-specific another technology that FCA uses to create ‘combination of things’. on-demand parts for prototyping: industrial The ability to deliver innovative, high- 3D printing, also referred to as Additive quality cars depends on the ability to ‘think Manufacturing. premium’ for customers while ‘building Compared with conventional premium’ with workers across vehicle manufacturing, where machining is subtractive, segments. Information technology plays a key meaning that material is gradually removed in role in this progressive transformation of work shaping a component, this technology shapes processes, by: them by adding layers of material. 3D printing: n optimising collaboration and integration n permits much greater complexity when between humans and technology; shaping, opening up new possibilities in areas n maximising the added value we can glean such as aerodynamic design; from data and information gathered through n improves time-to-market, by enhancing the many thousands of actions required to speed to production and prototyping; produce a complex product like a car; n significantly reduces material use, waste n advancing the adoption of cybersecurity generation and energy consumption standards for connected systems; associated with these activities. n accelerating the paradigm shift in terms of worker skills and mindset. ‘Less is better’ is not simply a lifestyle trend that is becoming increasingly relevant FCA has recently implemented a new for customers – and millennials in particular. It approach to manufacturing through the redesign is becoming the central paradigm for the hard of plants as ‘digital factories’ based on the manufacturing industry as well. Operators during the assembly stage have direct access to real time manufacturing data through integrated modular factory model. A completely In recent years, FCA has continued to wearable devices new Information and Communication develop its know-how and technological 37

FIAT CHRYSLER AUTOMOBILES

Alfa Romeo Stelvio 2017. Manufactured at the FCA plant in Cassino (Italy)

more than 1,400 robots, and more than 6,000 The Cassino plant and the The connected devices, including smartphones Stelvio illustrate how FCA has conceived and and smartwatches that connect the built an i4.0 value chain combining – at the shows how FCA applies worker to the interconnected experience of same time – speed of change with processes manufacturing a vehicle. and products. FCA has transformed the rapid speed of change to The plant offers high standards of efficiency, change in technology into an i4.0 business workforce ergonomics and eco-sustainability. model that connects our plants, our suppliers processes and products It has sent zero industrial waste to landfill since and our dealers, up to the final customer. 2000. It has a zero carbon footprint: 100% of This net of people, processes, products electricity used in industrial processes comes and services allows manufacturing data capabilities in this area. The Mirafiori plant from renewable sources, including on-site solar to be transformed into information, which in Turin, Italy, hosts the FCA Center of power generation. The plant also plans to be fully then generates smart interactions within all Competence for Additive Manufacturing that self-sufficient in terms of water usage; through elements of the FCA value chain. supports product development from design innovations such as dry scrubbing technology, We support sustainable innovation to testing, with a total of more than 14,000 in the paint shop zero water is withdrawn from through a partnership of man and machine to components produced in 2016. The Center local resources for industrial purposes. develop and manufacture mobility solutions for works closely with Italian and international our customers. universities and experts to spread the technical Supporting sustainable innovation Looking toward the future, there are infinite know-how globally across the Group. The Alfa Romeo Stelvio is the most recent technical connections that can be created and The adoption of 3D printing is a clear example of how we design and build premium fostered between the people and machines example of an innovation that is revolutionary value for our customers. The Stelvio represents that engineer and manufacture our vehicles, and sustainable at the same time. This the positive impact that i4.0 can have on and the end driver. technology was applied for the creation of a few a product. It features a full array of cutting-edge thousand prototype parts during development technical solutions such as the world premiere of the Alfa Romeo Stelvio, manufactured at the Integrated Brake System (IBS), Autonomous Cassino plant, in Italy. Emergency Braking (AEB) with pedestrian One of FCA’s most advanced examples recognition and a full carbon fibre crankshaft. of i4.0 today is the Cassino assembly plant in The Stelvio features an outstanding power- Italy, where the Alfa Romeo Stelvio and Alfa to-weight ratio, thanks to the extensive use Romeo Giulia are manufactured. The Cassino of ultra-lightweight materials: carbon fibre for plant figures speak for themselves: over 11,000 the crankshaft and aluminium for hood, doors, UNA-UK thanks Fiat Chrysler Automobiles for its part numbers, an automation level assured by fenders, lift gate, engine and suspension. generous support for Climate 2020