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World Class Manufacturing
Starting from 2017 OCAP production plants adopted the World Class Manufacturing system, a structured, strict and integrated production methodology that involves the whole organization, from safety to environment, from maintenance to logistics and quality.
The OCAP Group
OCAP can count on different production and distribution units.
The Holding, O.C.A.P. S.p.A., which includes only Direction, Supervision and Coordination functions, has its headquarters in Valperga (Turin), Italy.
History
In the mid-70s, Ivano Giordano created a small handicraft company named O.CA.P. S.n.c. (acronym of “Officine Canavesane di Precisione”, meaning Precision Workshops of the Canavese area)
Automated Processes, OCAP Italia
The OCAP group is highly specialized in designing, producing and selling a wide range of chassis mechanical parts: suspension joints, track control arms, silentblocks, tie rod ends, steering rods and other components belonging to the steering and suspension systems and generally applied to vehicles equipped with steering wheels.
OCAP’s structure and markets have constantly grown over the years, thus transforming the original single entity into a leading company managing a group that operates at an international level. Following a continuous improvement approach, OCAP has achieved excellent performances by consolidating partnerships with well-known manufacturers belonging to the automotive, trucks, earth moving machines and agricultural sectors.
Thanks to its technologically advanced R&D, Engineering and Testing Departments, the OCAP Group competitive advantages can be identified with its high specialization level, its flexibility and its co-design activity, which means its ability to offer a complete product development service and to produce components that satisfy the most demanding customer requirements.
OCAP efforts are aimed at methodological improvements and product/process implementation in order to maintain its technological leadership.
Testing Area, OCAP Italia
Robotic warehouse, OCAP International
OCAP can count on different production and distribution units.
The Holding, O.C.A.P. S.p.A., which includes only Direction, Supervision and Coordination functions, has its headquarters in Valperga (Turin), Italy.
O.C.A.P. Italia S.r.l. is also located in Valperga. It is the industrial site, where five production departments are operative three shifts a day; the technologically advanced warehouse for rough parts and semi-finished products, the R&D Departments, the Design and Testing units are also located here.
The impressive logistic centre of AM distribution, the O.C.A.P. International S.r.l, is based in Oglianico, a few kilometres from Valperga; it is a fully automatized warehouse for the storage and distribution of the AM products.
OCAP most recent production units are located in Asia: the Ocap Chassis Parts Pvt. Ltd. in Bhiwadi, State of Rajastan (India) and the Ocap Chassis Parts (Kunshan) Co., Ltd. in Kunshan, Province of Jiangsu (China).
The globalization of the company structure achieved its latest goals with the creation of the O.C.A.P. International S.r.l. representative office in Moscow (Russia) and of the company OCAP France S.a.s. in Cannes (France).
OCAP Italia - 45° 22' 13.551" N, 7° 40' 34.842" E
S.S. 460 Km26,700 Loc. San Martino
10087 Valperga (TO)
Italy
OCAP International - 45° 22' 13.551" N, 7° 40' 34.842" E
Strada da Fraz.San Grato a Via Cerini di Busano
10080 Oglianico (TO)
Italy
OCAP Chassis Parts (Kunshan) Co., Ltd. - 31° 21' 31.745" N, 121° 4' 29.596" E
No. 218 Huan Lou Road, Kunshan Development Zone
215300 Kunshan Jiangsu Province
China
OCAP Chassis Parts Pvt. Ltd. - 28° 12' 59.14" N, 76° 52' 21.14" E
A-1221 & A-1230, RIICO Industrial Area, Ghatal Bhiwadi – Distt. Alwa
301019, Rajasthan
India
1975
In the mid-70s, Ivano Giordano created a small handicraft company named O.CA.P. S.n.c. (acronym of “Officine Canavesane di Precisione”, meaning Precision Workshops of the Canavese area) located in Busano (Turin). Originally devoted to milling, turning and mechanical manufacturing, O.CA.P. soon specialized itself in the production of steering and suspension parts for automotive applications.
1982
In 1982 the company moved to Feletto (Turin) and, in the same year, a second handicraft company, the GIESSE 80 S.n.c., was founded in Feletto, too.
1984
In 1984, O.CA.P. S.a.s. merged with GIESSE 80 S.a.s. to create O.C.A.P. S.r.l.
1990
In December 1990, O.C.A.P. S.r.l. turned into the current privately held company named O.C.A.P. S.p.A.
1995
In August 1995 the new Ocap S.p.A. headquarters were inaugurated in Valperga.
2000/2001
OCAP continued its growth with the acquisition of MB Technologies S.r.l. seated in Rivara (Turin) in June 2000 and of PD S.r.l. based in Busano (Turin) in July 2001. Both companies were qualified in the production of steering and suspension components for trucks, earth moving machines and agricultural vehicles.
2002
Through the definition of an ambitious international investment plan, OCAP was able to react to the market changes and to adapt itself to the various requirements of its customers.
OCAP Chassis Parts Pvt Ltd., the production plant located in Bhiwadi (state of Rajastan – India), was built in January 2002.
2004
In 2004 the rationalization and implementation of the logistic service was achieved with the creation of the innovative and impressive pole of distribution based in Oglianico (Turin), dedicated to the management of After Market orders and deliveries.
2007
The globalization of the company reached a further goal in July 2007 with the creation of Ocap Chassis Parts (Kunshan) Co., Ltd. in Kunshan, province of Jiangsu (China), which produces high technology components for steering and suspension systems.
2012
During 2012 the group grows with the creation of the O.C.A.P. International S.r.l. representative office in Moscow (Russia) and of the company OCAP France S.a.s. located in Cannes (France).
2013
After almost 40 years on the market, OCAP presents its new logo.
2015
Ocap increases its presence worldwide with the creation of the O.C.A.P. do Brasil in São Paulo.
Since 2017, OCAP manufacturing plants have adopted the World Class Manufacturing (WCM) system, a structured, strict and integrated production methodology that involves the whole organization, covering safety, environment, maintenance, logistics as well as quality.
The main target of WCM system is to keep improving all production performances in order to guarantee product quality and meet customer’s expectations. The projects developed within the WCM, which rely on a strong involvement all the employees, have as common goal the systematic reduction of losses and waste, up to the ultimate result of zero accidents, zero waste, zero failures and zero stocks.
WCM is based on the systematic reduction of all types of waste or loss, and on everyone's involvement (at all hierarchical levels of the corporate), through the rigorous application of methods and standards.
WCM is focused on building a production system where:
- The sensitivity for safety is a basic value.
- The customer's voice reaches the workshop.
- Leaders are fond of standards.
- No kind of waste and loss is accepted.
- The methods are applied with rigour and tenacity.
- All anomalies/faults are made visible.
- The involvement of people is the engine of change.
The WCM is depicted as a temple supported by 10 technical pillars (pilar).
Each pillar addresses a topic and represents a scope of action in a technical area:
- Safety – Workplace Safety
- Cost Deployment – Economic loss sources
- Focus Improvement – Improvement focused on a specific problem
- Autonomous Maintenance – Workplace Organization
- Professional Maintenence
- Quality Control
- Logistic / Customer Services
- Early Equipment Management, Early Product Management – Acquisition strategy related to the means of work / processes
- Enviroment – Environment and exploitation of energy equipment
- People Development – Development of staff skills
These technical pillars are followed by 10 managerial pillars as well. The managerial or operational pillars constitute the actions that the WCM leader or the plant manager must carry out, aimed at promoting the commitment and self-responsibility of the different personnel in charge for each individual pillar.
- OPL One Point Lesson
- SOP Standard Operating Procedure
- SMP Standard Manutentive Procedure
- 4M MAN/METHOD/MATERIAL/MACHINE method of breaking down the problem to detect sensitive areas
- 5W 5 WHY ask and iterate questions about the reason for a phenomenon
- 5W+1H WHAT/WHERE/WHEN/WHICH/WHO/HOW Position the phenomenon within these items
- 3M Objective assessment of the workplace
- KAIZEN Specific improvement projects
- KPI Key Performance Indicators – Objective result indicators
- KAI Activity indicators (see Kaizen)
WCM’s goals aim to achieve the “zero” value in different areas: defects, stocks, inefficiencies, downtime, bureaucracy, customer dissatisfaction, etc.
To reach zero, the improvement must be obviously continuous.
