FCA Etobicoke Casting Plant Becomes Latest Bronze World Class Manufacturing Facility

March 1, 2019 , Windsor, Ontario -  The Fiat Chrysler Automobiles (FCA) Etobicoke Casting Plant has been awarded bronze status for its efforts in implementing World Class Manufacturing (WCM). It becomes the 23rd North American facility to reach the milestone award level and the first plant to be awarded in 2019.
 
World Class Manufacturing is a methodology that focuses on eliminating waste, and improving quality and safety in a systematic and organized way. WCM engages the workforce to provide and apply suggestions on how to improve their jobs and their plants, promoting a sense of ownership. WCM was first implemented by Fiat in 2006 and introduced to Chrysler Group as part of the alliance between the two companies in June 2009.
 
The 77-year-old Etobicoke Casting Plant earned bronze after receiving a minimum of 50 points in 10 technical and 10 managerial pillars following a two-day independent audit held on Feb. 27 and 28.
 
The plant demonstrated clear WCM know-how and competence through employee-conducted pillar presentations and a review of projects implemented across the shop floor. The bronze designation recognizes the long-term commitment of the workforce to making significant changes that can secure the future of a facility.
 
“Reaching bronze is a significant accomplishment that confirms the Etobicoke workforce’s understanding and commitment to the WCM methodology,” said Carlo Materazzo, Head of World Class Manufacturing. “Their dedication to implementing WCM best practices has improved the plant’s operations and the products they deliver to their customers. I want to thank all of the Etobicoke employees for embracing WCM as a way of life.” 
 
During a WCM audit, zero to five points are awarded for each of 10 technical pillars, which include safety, workplace organization, logistics and the environment, and for 10 managerial pillars, such as management commitment, clarity of objectives, allocation of people, motivation of operators and commitment of the organization. Bronze is awarded to plants that earn 50 or more points, followed by a silver designation if a score is achieved between 60-70 points. Plants that reach gold score between 70-85 points and World Class is awarded for 85 points or more.
 
There are 10 North American plants that currently hold a silver designation, having been elevated from bronze after receiving a minimum of 60 points during an audit. Silver is awarded to plants that have taken a preventative approach to implementing the WCM methodology throughout the facility. The silver plants are:

• Windsor (Ontario) Assembly Plant
• Dundee (Michigan) Engine Plant
• Toledo (Ohio) Assembly Complex
• Saltillo (Mexico) South Engine Plant
• Mack Avenue (Detroit) Engine Plant
• Saltillo (Mexico) Van Assembly Plant
• Warren (Michigan) Stamping
• Toledo (Ohio) Machining
• Sterling Stamping (Sterling Heights, Michigan)
• Tipton (Indiana) Transmission Plant

In addition to Etobicoke Casting, there are 12 other facilities that hold the WCM bronze designation:

• Saltillo (Mexico) Truck Assembly
• Toluca (Mexico) Assembly 
• Trenton (Michigan) Engine Complex
• Brampton (Ontario) Assembly 
• Indiana Transmission Plant II (Kokomo, Indiana)
• Belvidere (Illinois) Assembly
• Kokomo (Indiana) Transmission Plant
• Indiana Transmission Plant I (Kokomo, Indiana)
• Kokomo (Indiana) Casting
• Warren (Michigan) Truck Assembly
• Jefferson North (Detroit) Assembly Plant
• CPK Interiors, Port Hope (Ontario)

About Etobicoke Casting Plant
Originally built in 1942 by the Canadian government to support the World War II effort, the plant began operations as Alcan Aluminum to produce sand and permanent molds for military aircraft applications. Twenty-two years later, it would be acquired by the Chrysler Corporation with a major expansion added in 1965.
 
In 1998, further expansion to the facility was completed to accommodate a new piston cast process and, specifically, the addition of tooling and equipment for the high-pressure die casting department.
 
In 2010, the Company announced a $27.2 million investment for new tooling to produce front and rear crossmembers. This new technology investment has also improved the plant’s quality, testing and inspection processes.
 
Nearly 300 people work over three shifts at the 285,000-square-foot plant, producing aluminum die castings, such as adapters, powertrain mounts, transfer cases and stators, for a variety of Chrysler, Jeep®, Dodge and Ram vehicles that are assembled at plants in the U.S., Canada and Mexico. The plant’s central location just outside of Toronto plays an integral part in both inbound and outbound deliveries from suppliers, as well as the Company’s manufacturing locations. In 2014, the plant celebrated its 50th year of producing die cast parts for FCA US.
 
FCA Canada
Founded as the Chrysler Corporation in 1925, FCA Canada Inc. is based in Windsor, Ontario, and celebrates its 97th anniversary in 2022. FCA Canada is a wholly owned subsidiary of FCA, a North American automaker based in Auburn Hills, Michigan and member of the Fiat Chrysler Automobiles N.V. (FCA) family of companies. FCA Canada has approximately 440 dealers that sell Chrysler, Dodge, Jeep®, Ram, FIAT and Alfa Romeo products, as well as SRT performance products. The company also distributes Mopar and Alfa Romeo parts and accessories. In addition to its assembly facilities, which produce the Chrysler Pacifica, Chrysler Pacifica Hybrid, Chrysler Voyager and Chrysler Grand Caravan (Windsor) and Chrysler 300, Dodge Charger and Dodge Challenger (Brampton), FCA Canada operates an aluminum casting plant in Etobicoke, a research and development centre in Windsor, and has sales offices and parts distribution centers throughout the country.