32 - Drees & Sommer

OPTIMAL CONSULTING ON FACTORY UPGRADE
Fiat: High value-add through
efficient production workflow
Drees & Sommer is carrying out a project audit for a factory extension and the production
launch for a new Fiat model in Kragujevac, Serbia. The factory – which dates back to the 1950s –
is to be completely rehabilitated and modernized. The Fiat group is investing approximately
one million Euros in car production at the new site.
With its brands Fiat, Lancia, Alfa Romeo,
Abarth and Maserati, Fiat Group Automobiles
is one of the world’s top ten
automobile manufacturers. It is currently
undergoing structural change. On the
one hand, its partnership with Chrysler
should lead to synergy effects, while
on the other hand the company plans
to continue internationalization of its
brands and expansion of production
capacities in ‘low-cost countries’. In this
context, from mid-2012 the successor
Scope of audit management by Drees & Sommer
model to the Fiat Idea will be manu-factured
at the former Zastava plant in
Kragujevac, Serbia, managed as a joint
venture between the Serbian state and
Fiat. The factory is to be extensively
modernized for the launch of the new
model.
Investment: One billion Euros
Investment of some €1 billion is planned,
resulting in a production capacity of
more than 150,000 cars per year. As
Schedules
Development Production Installation Startup
Energy, buildings, service
Utility supply
Press shop
Car body construction
Quality assurance
Paint shop
Logistics
Final assembly
Phase in/out 188
Interfaces for IT / product / suppliers / personnel
part of a so-called brownfield project,
the existing factory will be completely
adapted to meeting the requirements of
“best practice” automobile production.
Following completion of construction
work, the installation of newly developed
production processes and equipment
will begin. These will set new standards
in comparison to other Fiat Group sites
worldwide and are characterized by
greater manufacturing content.
Quality Organization Communication Scheduling Reporting
Costs
Project audit
Drees & Sommer is supporting the
project by carrying out a project audit.
During the construction phase as well
as during the development & integration
of the production plant, all processes
relevant to on-schedule, within-budget
implementation to the required quality
standards will be continuously monitored.
Any deviations will be recorded,
and any necessary countermeasures
initiated.
The immense size of the production
halls – some of which are in a critical
condition – has to be emphasized. As
a result, substantial decontamination
work has to be carried out in parallel to
extensive remodeling and upgrading.
At the same time, it must be ensured
that production can continue unhindered
while this work is carried out.
Regular Reporting to client
The key task of the Drees & Sommer
project team is to identify risks in the
project and to communicate these to
the client.
The Managing Director of Fiat Automobiles
Serbia (FAS) and group management
in Turin are kept informed about
the current project status, any improvement
measures implemented and the
overall progress of the project in regular
order to reports. This regular reporting
by Drees & Sommer delivers a sound
basis for decisions on control measures
by both Fiat management and project
management.
Client
Fiat Automobiles Serbia (FAS), Kragujevac
Project duration
October 2010 – May 2012
Key project data
– Production capacity over 150,000 cars
– Investment volume: Approx. €1 billion
Drees & Sommer services
– Audit management
Value-add achieved for client
– Recommendations regarding optimal
processes taking production plant and
their integration into account
– Identification of process risks
– Support through production engineering
and structural engineering expertise
Drees & Sommer identifies project risks for
the upgrade and expansion of the former Zastava
factory in Serbia, at the same time reviewing
process for the Fiat production launch
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