QUALITY AND SUBSTANCE
 

The Fiat Croma is a car that embodies substance and quality. It is the fruit of a "robust" project for which the company drew on its best resources and most sophisticated methodologies. The result is a reliable, quality car, which boasts exclusive equipment in the field of safety and comfort, backed up by a long list of dedicated services. All these features make the new Croma a car that is outstanding value for money, thanks to the combination of contents, running cost and trade-in value.

First of all, "quality" is what the customer perceives immediately from the harmony that the car transmits, at first glance and first touch. This perception is confirmed by the excellent performance, obtained thanks to state-of-the-art engines and superb overall comfort: from the handling to the acoustics, the loading space and the interior finish, the colours and the embossing. To satisfy the demand for quality, the team that worked on the Croma project adopted a very strict engineering process based on a solid platform that had a very clear goal: to create a new class of car that would pool the advantages of different types of car: the roominess of a people-mover, the loading space of a station wagon, and the styling and dynamism of a saloon. In this sense, the term "quality" applied to the new Fiat model reflects a working philosophy, a practical choice that has produced a car that is 100% dependable, immediately and uncompromisingly.

The Fiat Croma is an innovative car, born under the sign of quality. And it sets very high quality standards, which were pursued from the first stages of the project. That is not all. The quality is also expressed in the choice of materials, and the attention to detail, as well as in the overall results and the way the many skills involved in the Croma project were combined. We cannot overlook the fact that during the various experimental stages, the prototypes travelled over 3 million kilometres to test the car in all types of road and climate conditions. The manufacturing process at the Cassino plant was tested in advance of the normal development procedure, and the process verification was performed directly on the plant's assembly lines, And finally, the high quality controls were raised even higher by the introduction of a 100 km test drive for 100% of the pre-production cars.

In other words, the new Croma is another step forward for Fiat in its striving after quality, a value that we find in the Cassino plant which is one of the leading players in the entire process.

The Cassino plant

The plant in Cassino (Frosinone), where the Fiat Croma is built, is a centre of excellence in the worldwide automotive industry. In 1972 Fiat chose the city, which lies south of Rome and is famous for its historical Benedictine monastery, as the site for an advanced manufacturing plant. From the start, the Cassino plant played an important role: it was here that the Robogate system was introduced for the first time, before it became the mainstay of the automation of car plants all over the world. It was here that Fiat decided to invest in technology and quality for the Fiat Croma, developing an innovative manufacturing model specifically for the new car, based on a balanced mix of advanced automation and human intervention to control the quality which supports the technology on the Fiat Croma. Today, Cassino represents the state of the art among car manufacturing plants the world over. There is no other plant in Europe of a similar technological or organisational level in terms of manufacturing processes and techniques.

The plant is located in central Italy, and it is also located centrally with relation to the other Fiat Auto manufacturing plants in the country; it stands in an area of 2,033,072 square metres. The plant includes panelling, painting and assembly shops, while much of the site is occupied by Fiat Auto suppliers, which are thus perfectly integrated in the manufacturing process and ready to intervene directly in the various stages. The Cassino plant currently has a workforce of about 3500 Fiat Auto employees, whose average age is 45. The working day is divided into two shifts, 5 days a week. Since it was inaugurated in 1972, the Cassino plant has built numerous important Fiat models (in 2004 it celebrated 6 million cars manufactured since it opened), and today it builds the Fiat Croma and Fiat Stilo. It has a manufacturing capacity of more than 250,000 cars a year, at a daily rate of about 1000 cars, almost one a minute.

The Cassino plant has evolved constantly, from a conventional manufacturing layout to the Robogate and the highly automated plant, right up to the new manufacturing model, known as the "integrated modular plant", which is the most advanced system in the automotive industry.

When the Fiat Stilo went into production, the manufacturing process at the Cassino plant was completely reorganised, with an investment of almost Euro 400 million and over one thousand days of training for the plant's workforce. This transformation was based on the interaction of different factors:

These four big changes played a decisive role in improving the capacity of the manufacturing process, which translates into greater manufacturing precision and better product quality.

The re-engineering of the manufacturing process and innovation for quality

The re-engineering of the manufacturing process optimised work on the assembly line in terms of quality and efficiency. It regarded the panelling and assembly areas in particular, although the whole process was re-engineered: every single step was made more efficient. A great deal of space is reserved for quality controls: during the entire process, each Fiat Croma is subjected to over 200 checks, most of which are electronic.

1) Panelling. This is an essential area for the quality of any car, and one where a high degree of automation is decisive to guarantee the quality of the product. The level of the technology is evident from the figures: 437 spot welding robots, 18 continuous seam welding robots, 916 welding guns, a total of 280 actions. Manufacture of the Fiat Croma caused numerous innovations to be introduced in this area: 43 Comau NH4 robots; 45 Comau H4 robots; 12 Comau M1, S2 and X1-500 robots: 14 CO2 welding stations; 25 Tucker pin welding stations; 107 suspended manual welders; 5 fixed welding machines. In all there are 12 specific automatic assembly lines, 2 specific semiautomatic lines and 12 manual islands.

In 2004, about 100 new NH4, H4, M1, S2 and X1-500 welding and handling robots were added to those already in use. They are equipped with electric motors and electric welding guns which guarantee a hotter, cleaner, and therefore better quality spot weld. Each Fiat Croma receives 4,208 spot welds (2,858 of which automatically), 32 indirect spot welds, and 173 Tucker pins are applied, 3,215 mm welded by strong CO2 MIG welding and 700 mm by braze welding. The panelling shop also includes two opto-electronic second generation laser control stations for the chassis and the bodyshell. They are both of the "single tool" type and work on-line, on both the Croma and the Stilo. This dual control guarantees the perfect geometry of the car skeleton; the check performed on the chassis before the bodyshell check is important because it must guarantee the quality of a part that will influence the engineering, and it is essential to guarantee precision in the shapes and proportions because the excellent agility, driveability and roadholding depend on them.

To this we must add the innovation of the "single tool" system. This is a Fiat Auto exclusive, and it verifies the geometry of the chassis and bodyshell separately from the support on which they travel, so that any geometrical errors in the support will not affect the laser measurement. It is a solution that represents a real element of excellence in the manufacturing system of the new model, because it has practically eliminated any possibility of incorrect measurements during the laser control.

The "Open gate" system that replaces the earlier Robogate system guarantees even more precise subassembly and assembly of the sides, as well as more precise welding, because of the ease with which the mechanical arms of the robot can move inside the bodyshell. The "Open gate" systems were designed specifically for the Fiat Croma and Fiat Stilo. And finally, at Cassino, spot welds sealing is verified by ultrasonic sensors. The sensors test the spot welds and certify or reject the quality of the weld on the basis of the spectrum of response.

2) Assembly. Significant innovations have also been introduced during the assembly of the Fiat Croma in Cassino. First of all, the bodyshell conveyor system was re-engineered, introducing the auto-motor technology into the assembly process to eliminate annoying background noise and to obtain optimal comfort in the workplace. Control units with a new generation electro-pneumatic lift system have also been introduced, to improve the coupling of the mechanical parts to the bodyshell during the assembly of the bodywork.

And finally, the preparation and spreading of the glue on the windows of the new model is carried out by a latest generation robotised system. And to avoid mistakes when picking components, the glass is chosen by computer and a multifunction display. Bodyshell bonding is entrusted to the sensitive hands of the workers who ensure that the glass is in the correct position whatever the condition of the process.

The contribution of Fiat Group companies

A car with a strong personality, yet also a cutting-edge car in terms of equipment, power units and mechanicals. This was the brief given to the Fiat engineers and technicians. To achieve its goal, the company deployed its best resources and ensured that maximum quality and reliability standards were applied throughout the product development and construction process. It also developed a profitable co-operative relationship with its outside suppliers and some Group Companies including Magneti Marelli, Centro Ricerche Fiat, Elasis and Comau.

Magneti Marelli

Magneti Marelli has made an important technological contribution to the development of the new Fiat Croma, starting from the exterior, for which Automotive Lighting designed the headlights, and manufactured them in its plant in Venaria, outside Turin. There is a choice of two types: halogen headlights and bi-Xenon headlights which exploit the advantages of xenon light for both the dipped and the full beam. This technology is typical of top-of-the-range models, and produces a light flow that is almost double the usual beam, while absorbing one third less energy. The light clusters, which help to convey the car's solid, important personality, and the third brake light, were also the work of Automotive Lighting.

Magneti Marelli's contribution to the "engine control system" was focused in particular on the Diesel versions which are fitted with the DTM (Diesel Throttle Module), a drive-by-wire throttle valve adopted on the 1.9 and 2.4 Multijet versions, to make it easier to turn the engine off. The 1.9 version also fits a variable geometry plastic air manifold with electric drive that enhances performance, and reduces consumption and emissions.

Magneti Marelli technology is well represented in the field of electronic systems: the car is equipped with the Connect Nav Plus infotelematic system, which includes a satellite navigator, radio, CD and MP3 file player, hands-free GSM dual band radio and voice controls. The device incorporates a 6.5" TFT colour monitor and is able to receive and manage the RDS-Traffic Message Channel, information regarding traffic and weather conditions on a set route. A new, more legible, attractive graphic interface also makes its debut on the Croma.

The control panel was also designed by Magneti Marelli: it features an alphanumerical LCD display for perfect visibility of all data regarding the trip and the vehicle, and a B-Can connection to exchange data with the rest of the vehicle and the diagnostic system. Yet another example of a new electronic system is the "body computer", a control unit that acts as a gateway to manage the CAN network, and other functions such as the immobiliser, diagnostics, sensors, light controls and fuel level.

And finally, the high levels of comfort and safety are guaranteed by the front and rear suspension system by Magneti Marelli that equips all versions of the new car.

Elasis

To achieve the global comfort objectives on the car, Elasis, Fiat's Research Centre in Southern Italy, carried out a series of tests using dedicated test benches where a set of measurements can be performed extremely precisely and repeatedly. The roller dynamometric test rig of the Pomigliano d'Arco laboratories was able to verify the elastic characteristics of the engine support blocks.

This rig also allows engineers to simulate all types of driving conditions, including full throttle acceleration, deceleration and gear changes, deciding the main parameters by which to monitor the performance of the blocks. This made it possible to verify the consistency between the drawings and the actual components, and therefore the performance of the specific engine suspension system.

The Elasis engineers performed other tests on the soundproofing, i.e. the degree of acoustic insulation, taking measurements in a semi-anechoic cell. This translates into what the customer perceives as a "quiet car".

And finally, Elasis worked to guarantee perfect integration, in the manufacturing area, between the mechanical parts and the vehicle, right in the Cassino plant, as well as performing specific NVH (Noise-Vibration-Harshness) analysis.

Centro Ricerche Fiat

The Centro Ricerche Fiat engineers' role in the development of the new Croma was to put the best analysis and comparison methodologies at the service of the various activities, as part of a team whose aim was to make the car safer, more practical and more comfortable.

Crash and biomechanical methodologies ensure that the passenger cells effectively protect the occupants and that the front of the car is compatible with vulnerable subjects (pedestrians, cyclists, etc.), respecting the demands of current and future legislation.

Thermofluid dynamics and climate control methodologies make it possible to define interior comfort and wellbeing in terms of climate and air quality.

Vehicle handling methodologies have made it possible to achieve an enjoyable, predictable drive in all speed, manoeuvring and grip conditions, through painstaking design of the suspension and controls (steering, brakes, etc.)
 

Physical and cognitive ergonomics, supported by the Virtual Reality laboratory, are employed in the correct design of the interior space and systems (seat, facia, etc.), the primary and secondary controls, the mobile parts and the communication interfaces, confirming the excellent ergonomic qualities (access, roominess, etc.), which have always been among the most important values of the FIAT brand.

CRF also played an important role in the development of the engines. The basic concept of the Multijet engines and their subsequent distinctive high performance (the 2.4 litre JTD delivers 200 bhp, which corresponds to more than 80 bhp/litre) rely on innovative technologies and calculation methodologies that made it possible to develop and to apply:

Comau

The company has contributed to the development of the Fiat Croma with 70 new generation robots, which work on the assembly lines of the Cassino plant, welding and producing a series of bodyshell components that include: the floor, front skeleton, front and rear doors, tailgate, bonnet, sides and roof, and even perform assembly operations for the entire bodywork. The introduction of the new model required only limited capital spending because it was possible to convert the existing tooling, with the result that the same systems can now produce two different models on a random basis, the Stilo and the Croma. This flexibility is obvious if we observe the bodyshell welding station which features the Openrobogate®, one of the most innovative products from Comau BW&A.

Another interesting application regards the robotised station that deposits the roof on the bodyshell; the roof is positioned automatically using a scanning system based on laser technology. These units use new generation Comau robots with a hollow wrist (containing all the wires that supply the welding guns), which have considerably cut programming costs and the time necessary to fine tune welding programmes.

For this project, Comau decided to carry out the process verification in the same plant where the car would be assembled, which meant a further reduction in capital spending. And to limit interruptions in the manufacture of the existing model, the plant was set up in an adjacent area (not involved in current manufacturing activities), and then installed in the main assembly lines without interrupting the original flow (during normal production halts).

And finally, the diesel engines are built in the Pratola Serra plant, also by Comau systems.

Services and main product features

The Fiat Croma is the ideal car for the modern family, but also for companies and professional people. As a result, Fiat Auto Financial Services have devised numerous personal purchasing formulae for these customers, on the major European markets. And the new model is offered in a comprehensive range in which everyone will find the Croma he or she wants. There are different solutions for different markets, but they are all excellent value for money, reflecting the many ways of interpreting and enjoying one's car. One of the most sophisticated of these is the CONNECT Nav Plus system.

Renting and Leasing the Fiat Croma

The innovative "long-term rental" formula relieves the customer of all the formalities related to direct management of the car because it is the rental company that deals with them: insurance and management of claims, ordinary and extraordinary maintenance, towing, roadside assistance and courtesy car, service and tyre changes, road tax, management of second-hand vehicles. All of this is covered by a monthly charge, with no capital investment.

Croma customers can take advantage of a particular rental formula called "Invitation to the test". This initiative allows them to familiarise with all the product's innovative features, and to choose one of the three solutions explained below at the end of the first twelve months, to meet their needs:

"Invitation to the test" also includes the bCONNECT Voice service, a real personal assistant, reached by a toll-free number from any land line or cell phone, who will advise customers during their travels, offering information about restaurants, places of interest, culture, museums, and traffic information. And finally, the purchasing formulas for the Croma obviously include leasing, with the possibility of including an extended warranty and or maintenance services. CONNECT Nav Plus On request, the Fiat Croma can be equipped with the CONNECT Nav Plus, a sophisticated state-of-the-art info-telematic system that incorporates a satellite navigator, radio, CD player, hands-free GSM dual band telephone, voice controls and bCONNECT services.

Positioned at the centre of the facia, the device offers a 6.5" TFT active matrix colour display which allows the driver to follow the indications of his chosen route on the display (and by voice messages). CONNECT is the telematic solution that puts technology at the driver's service and makes life on board more comfortable and easier during his journey: just by pressing the green button, the GPS/GSM network and the advantages of satellite communications, allow him to talk directly to an operator, a real personal assistant who is ready to answer any request for information in his own language. The various services available include:

The range

The new model is proposed in an extremely comprehensive range, in which everyone will find the Croma he is looking for. Different solutions are offered on different markets, but they all offer the same value for money, and reflect the many ways of interpreting and using the car. In Italy, for example, the range includes a choice of 4 engines (the 1.8 will be available at a later date), 5 outfits (Active, Dynamic, Dynamic Skyline, Emotion and Emotion Skyline); 9 bodywork colours, and 4 interior environments in two shades (dark grey or beige), available in a choice of fabric, velour, Castiglio and leather.

The new Croma range also offers every customer, even the most demanding, an opportunity to choose between different features which highlight the practicality and versatility of the model on one hand, while responding to the functional and emotional demands of the customer on the other.

Even on the first outfit, the Croma offers a level of equipment that is superior in terms of stylistic elegance and content.

To start with, the harmonious design of the new Croma is set off by a number of details which underline the careful stylistic refinement performed: the large headlights that taper onto the sides, the elegant large grille with its chrome frame, the wheelarches in relief on the sides which underline the car's power and elegance, the finely machined rear light clusters that create a Hi-Tech effect by day or by night, the chrome handles which adorn the sides, hinting at the luxury of the interior.

Like the exterior, the interior of the car represents a perfect balance between form and wellbeing on board: the facia links perfectly up to the door panels, incorporating the gear lever and the main controls at its centre, the elegant metallic grey or lacquered Bordeaux inserts (depending on the outfit) which highlight the elegance typical of Italian styling, the different types of fabric on offer which are elegantly repeated in the door panels for a striking chromatic effect.

In terms of product features, the Croma boats a vast, technologically advanced range. The most interesting are:

Active and passive safety

Infotainment

Climate comfort

Air distribution on the Croma is guaranteed by 12 vents (4 of which for the rear seats) which guarantee complete, effective climate control in the passenger compartment:

Comfort / driver's aids

Functionality

Styling