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“The joint Fiat-PA team accellerated ideas, and the process implementing them faster. New product designs improve existing and future model development.”

HARALD WESTER, CHIEF TECHNICAL OFFICER, FIAT GROUP AUTOMOBILES

Fiat – supporting the turnaround with a revolutionary approach to cost control

PA Consulting Group worked with Fiat Group Automobiles to support a cost-reduction programme for annual purchasing volume of more than €1 billion. Fiat had already aimed to reduce costs by several hundred euros per car, with a total annual cost reduction target above €100 million by end-2007. PA accelerated this programme by adopting a strong methodology, initially focused on four models crucial to Fiat’s future success: Croma, Grande Punto, Alfa Romeo 159, Ducato.

PA’s approach created an understanding of all costs involved (components, supply chain, technical design), developed and captured cost-saving ideas. Using a unique cost model developed by PA - coupled to the knowledge of automotive manufacturing processes - the joint team determined the components' ‘should cost’ and investigated disparities between this and quoted price, and discussed these in detail with suppliers to agree savings. Finally, to analyse Fiat’s own vehicle design and parts complexity, 16 competitor vehicles were stripped down to compare their design with Fiat’s equivalents as well as to identify and quantify improvement ideas and potential cost benefits from technical changes.

This programme helped Fiat achieve its cost reduction objectives. From the beginning, the value of viable cost-saving ideas for the four models had trebled to over €100 million per annum. Of this, €80 million has already been realised within the same year.

“PA worked with the integrated multi-disciplined Fiat teams to significantly improve our way of working. In particular, the structured dismantling, evaluation and benchmarking of Fiat cars with competitors’ identified major improvement opportunities. It laid the groundwork for a tremendous increase in idea generation, evaluation and implementation - for both current and future models.”
Carlo Bassotto, Engineering and Design, Fiat Group Automobiles

“The impact on Fiat goes well beyond the four new models. Fiat has significantly improved its approach to costing for all its product ranges.”
Gianni Coda, Fiat Group Purchasing

To find out how PA can grow cost control in your business, please contact us now.