Alfa Romeo Cassino Plant

Production of the Fiat Ritmo, a new Italian mid-size car, was kicked off six years after the plant was opened.

This highly automated system was designed to facilitate and speed up the tasks of workers in the Body Shop.

The model came in three versions – sedan, wagon and van, named Marengo – and shared many components with the Tipo, such as the engines, the platform, the doors and the suspension.

The factory underwent yet another major technological advance when the Robogate was retired and replaced by the Open Gate system, which offered more efficient and accurate side panel welding.

Change Management involved organising WCM Academy activities in the Training Areas and trade schools in which all workers could learn and implement the procedures.

Overspray is sucked in by a flow of air and collected in special cardboard separation modules, called Eisenmann E-cubes, instead of being washed away with water.

The cataphoresis process, instead, uses the innovative Eisenmann E-Shuttle system, which features dipping and turning the body in the treatment bath.

This technology improves the amount of protective liquid covering the chassis gaps and is ideal for aluminium bodies.

Front and rear bumpers, dashboard shells, tunnel consoles and fuel tanks are made here for Cassino and for other FCA plants.

For instance, the special adaptive platforms automatically adjust the height of the workstation according to the stature of the person working there.

World Class Manufacturing (WCM) is the continuous improvement methodology adopted in FCA plants worldwide aimed at maximising competitiveness by eliminating waste, fostering personnel involvement and achieving high-quality standards.

[9] Work Place Integration (WPI), introduced in Cassino with the Giulia, is the approach used to make workstations according to better ergonomic standards.

[9] Respect for the environment The Cassino plant is characterised by the careful exploitation of natural resources, which has made it possible to achieve considerable results.

The chosen technologies have the goal of eliminating the need to draw water from local sources for the industrial process.