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INDUSTRIAL 3D PRINTINGFCA makes extensive use of industrial 3D printing technologies, also referred to as Additive Manufacturing, for rapid prototyping during the product development and pre-production phases. At the Melfi plant, prototype components can be printed directly from 3D computer models, avoiding the need to build special stamping presses, molds, or other equipment. Not only is this technology essential in improving time-to-market, but it also significantly reduces material use, waste production and energy consumption associated with these activities. SMART LOGISTICS AND INTEGRATED SUPPLIER PARKProcess improvements at Melfi include the continuous re-engineering of material flows in order to deliver only what is needed, where it is needed and at the right time. On-site logistics processes are designed according to the principles of World Class, which address requirements relating to safety, ergonomics, eco-compatibility and transport flow optimization. Changes in packaging for inbound parts and materials have led to a significant reduction in the use of raw materials and, consequently, the level of waste generated and handled at the plant. Another important dimension to the plant’s operating model is the level of integration with key suppliers. A 758,000 m2 integrated supplier park located next to the plant hosts a total of 18 key suppliers with 73 lines of components on-site. About 75 per cent of the plant’s component requirement needs are served directly by the supplier park, enabling a high level of vertical integration and optimized logistics flows and reducing the need for large inventories through just-in-time delivery. For distribution of completed vehicles, rail routes from the plant to the nearest seaport in Civitavecchia have been expanded, leading to significant savings in both economic and environmental terms.EXCELLENCE THROUGH ENGAGEMENTThe success of the progressive digitalization of the Melfi plant also reflects the high level of employee engagement and the adoption of a new mindset. The ambition of transforming Melfi into an internationally-recognized model of best practice quickly became a part of every employee’s mission. Central to this transformation was a series of change management initiatives together with the WCM framework, which targets the highest standards of excellence and bases its success on the level of workforce engagement. Employee know-how and proficiency were upgraded through technical training and leadership development programmes, developed primarily within the WCM Academy. Established in 2014, the Academy at Melfi is a living, high-tech laboratory that offers courses and special training initiatives through certified trainers. So far, employees at the plant have already received “THE IMPLEMENTATION OF WCM AT FCA PLANTS WORLDWIDE HAS BEEN AT THE FOUNDATION OF THIS TRANSITION TO A SMART FACTORY MODEL”98 TRANSPORT AND MOBILITY