More than 50 years later, and thanks to its stylistic and modern technological features, the new Fiat 500 represents the spark of another milestone along the lasting process of expansion. And this is where history starts again.

The 2012 Fiat 500 caters to a new generation of Americans who want their vehicle to be as engaging, individualized, ecologically responsible and technologically savvy as they are.

"Like the original Cinquecento a half-century ago, the new Fiat 500 changes the rules of personal transportation and delivers a new sense of individual expression and opportunity. At a time when America is getting back to basics with a fresh awareness of the environment around, the new Fiat 500 identifies with today's minimalistic attitude and delivers with state-of-the-art eco-friendly technology wrapped in world-class quality, craftsmanship and style," added Soave.

This modern-generation Fiat 500 offers safety, fuel economy, quality and advanced technology perfectly balanced with iconic Italian style. With its city-friendly four-passenger A-segment size, engaging driving dynamics, all-new fuel-efficient 1.4-liter Fiat MultiAir® engine delivering up to 38 highway mpg and a best-in-class 30 mpg city (with manual transmission), state-of-the-art BLUE&ME™ Handsfree Communication technology, seven standard air bags and new quality and refinement adaptations for the U.S. market, including an all-new six-speed automatic transmission, the 2012 Fiat 500 offers a driving and ownership experience unlike anything available today.

Reminiscent of the original Cinquecento, the 2012 Fiat 500 builds on the vehicle's global popularity. Since its initial launch in 2007, more than 500,000 Fiat 500 vehicles have been sold in more than 80 countries around the world. The model's unquestionable popularity is the result of the Fiat 500's great ability to deliver unmatched personalization options with advanced solutions in terms of quality, engine and passenger comfort. In addition to success on the sales front, the Fiat 500 has earned 60 international awards, including being named the 2008 European Car of the Year.

EXTERIOR DESIGN

The new 2012 Fiat 500 is the manifesto of the 'new Fiat,' a model that represents a new approach to personal transportation with its modern and simple design aesthetic, numerous personalization options, fashionable Italian flair and world-class craftsmanship. More than 50 years after the original icon, the new Fiat 500 once again highlights Fiat's forward thinking, perfectly tailoring a car for America's new sense of efficiency, individuality and style.

"Capturing the original Cinquecento's iconic looks and smart packaging in a contemporary, no-nonsense design, the new 2012 Fiat 500 is artfully blended with technical, cultural and creative aspects in a vehicle that is exactly right for the times," said Roberto Giolito, Head of Fiat Style. "Personally, I like to think of the Fiat 500 as the automotive equivalent of the iPod – sleek, simple, functional, user-friendly and inspired."

The new Fiat 500 respects the original Cinquecento innovative shape and function and evokes all of the emotions and memories that make any icon eternal and rise beyond traditional categories or paradigms. Even more importantly, the new Fiat 500 delivers exclusive Italian design and innovations to the American market.

Designed for the metro
The new 2012 Fiat 500 features city-friendly proportions and iconic Cinquecento cues, wrapped in modern Italian styling that conveys simplicity and strength.

Thanks to its short overhangs, bodyside made up of several superimposed layers and 'shell-like' roof, the new Fiat 500 features unmistakable proportions and a number of aesthetic features to give it an 'appealing' air while conveying solidity and robustness.

With its signature 'whiskers and logo' face, new circular projector headlamps and lower park lamps, the new 2012 Fiat 500 combines the family resemblance of the latest Fiat models with the distinctive elements of the original Cinquecento in stylistic harmony. To show its road-holding stance, the vehicle's front fascia tapers outward toward its large wheel arches and features horizontal chromed trim for an added touch of sophistication. Illustrating how the Fiat 500's form follows function, the upper fascia features a horizontal cooling duct for added design character and providing additional engine cooling, while the lower 'honeycomb' style grille integrates road-brightening fog lamps.

The new Fiat 500's body-side A-line slopes slightly at the front for a dynamic look, while its lateral section features clean surfaces and flared wheel arches to deliver a modern interpretation of the historic 500. To keep its design simple, the hood-to-fender seam is elegantly cut at the A-line. Filling the wheel wells are five unique wheel designs ranging from 15 inches to a sporty 16 inches with the '500' logo on the center caps. For more design character, new bi-halogen projector headlamps and restyled taillamps are visible from the side profile thanks to the way the Fiat 500's rounded sides link up to the front and rear. Providing enhanced durability, new lower-sill spats protect the bodyside from stone chips. Finishing the iconic profile, the roof pillars and shadow-line window molding form a continuous arc to neatly hide the upper edge of the doors.

Even the rear of the new Fiat 500 is stylized with its new signature chromed license plate brow, a motif from the original Cinquecento that was inspired by a bicycle saddle. To keep the rear design clean, the rear taillamps are neatly set between the edges of the liftgate, and the lighting functions are divided vertically following the door's cutline. For a contemporary look, the Fiat 500's rear window spans the width of the liftgate and meets cleanly at the pillar.

New Fiat 500 Sport features sportier exterior treatment
Matching its sport-tuned suspension, the Fiat 500 Sport features an all-new athletically styled front and rear fascia with larger 'honeycomb' grilles and flared aerodynamic treatment. Between its unique 16-inch aluminum wheels with Mineral Gray painted pockets, this Fiat 500 incorporates new bodyside sill cladding and a liftgate-mounted roof spoiler for a sporty appearance. Completing this athletic vehicle's design are Performance Red painted brake calipers, a chromed exhaust tip and gloss black shadow-line window trim.

Glass roof stylistically reinterprets the past
With modern functionality and design, the available glass roof on the new 2012 Fiat 500 gives a nod to the past with design references from the historic model. The famous canvas roof of the past has been replaced by a four-season-friendly glass roof. For a near seamless and harmonious design with the windshield, the sunroof (available in a fixed version or powered) delivers a linear and luminous roof design while providing additional highlights of the pillars' two arcs. Like the original Cinquecento, the new Fiat 500 with power sunroof maximizes outward visibility so its passengers can enjoy the beautiful world around.

Fourteen vivid and trendsetting exterior paint colors
The styling of the new 2012 Fiat 500 will be completed by a broad choice of metallic, non-metallic and pearl (tri-coat) paint colors. For maximum character, the Fiat 500 will be available in 14 vivid hues, including colors inspired by the vintage appeal of the first 500. True to the vehicle's heritage, the available colors in Italian include: Nero (black), Rosso (red), Bianco (white), Azzurro (blue), Grigio (gray), Argento (silver), Giallo (yellow), Mocha Latte, Verde Chiaro (light green), Rame (copper), Espresso, Verde Oliva (olive green), Rosso Brillante (tri-coat pearl red) and Bianco Perla (pearl white).

INTERIOR DESIGN

With its high attention to detail, no-nonsense design and numerous personalization options, the new 2012 Fiat 500's interior represents a new direction in personal transportation.

"The new 2012 Fiat 500's interior design is space efficient and stylish, while delivering absolutely everything that is required and nothing more," said Roberto Giolito, Head of Fiat Style. "The new Fiat 500's interior design perfectly balances practicality with comfort and convenience features while infusing Italian-by-design style and personalization options."

Fiat 500's interior design features simple elegance with timeless design features
For the new Fiat 500, simple does not mean 'bare' – instead it embraces a particular stylistic and constructive interpretation that strives for 'simplified enjoyment.' The passenger compartment is airy and roomy, an environment designed to be comfortable and enjoyable for any destination.

The interior design theme of the new 2012 Fiat 500 is an artistic blend of clean lines and conveniently located features inspired by the historical model. Through the available leather-wrapped steering wheel, the Fiat 500's single concentric instrument cluster features the speedometer, tachometer and trip computer in a distinct and effective manner. Integrating the latest in portable vehicle navigation for improved route guidance, the instrument cluster features a central LCD monitor that shows pictograms from the TomTom® navigation with BLUE&ME™ Handsfree Communication. These elements, together with a highly integrated center stack with a uniquely designed radio and climate control system, can be ordered in Ivory or Black for an extra level of personalization while also influencing the interior theme to be more sporty or vintage.

The Fiat 500's instrument panel continues the perfect blend of modern simplicity with iconic Italian styling. The upper instrument panel is designed to convey a sense of refinement and elegance and features color-matched exterior accents for added detail. Frequently used vehicle buttons are highlighted with chromed circular rings and centrally located on the exterior-matched instrument panel trim for a premium appearance. The lower instrument panel highlights the new Fiat 500's space utilization with large- and small-sized storage spaces to keep mobile devices at a convenient reach.

A new passenger glove box stores valuable items, while concealing the BLUE&ME Handsfree Communication system's USB port for instant integration of mobile devices including an iPod. For an integrated look, the new automatic- or manual-transmission shifter and bezel are ergonomically located into the lower instrument panel and feature a mechanically styled shift knob accented in black, chrome or leather depending on the model.

The new Fiat 500's interior features highly detailed driver and passenger seats available in 14 color and material combinations for maximum personality with an added touch of personalization. Inspired by the historic Cinquecento of the 1960s, the new seats offer the same unique split-color effect: monotone fabric at the bottom and the upper seatback, while the head restraint is matched to the Ivory or Black interior environment. Uniquely designed cloth seats provide an upscale look and feel, while premium leather seats are available in traditional Black, a Brown hide or ultra-sporty Red and deliver a sophisticated look.

Continuing the clean interior design theme, the new Fiat 500's door panels feature a contrast between the upper area upholstered to match the seats, while the surrounding area elegantly incorporates large map pockets and a specially designed space-saving BOSE® premium audio system. Paying homage to the past, the chromed 'hook' door handle shape recalls one of the most remembered features on the original model while integrating modern-day power door locks.

Intelligently designed cabin provides the new Fiat 500 with maximum interior space
Thanks to careful analysis of the interior space, designers of the new 2012 Fiat 500 made an amazingly roomy and capable cabin within its city-friendly size. With built-in storage spaces including two in the instrument panel, map pockets in the door panels, another below the center console's shifter bezel and one below the passenger seat, the Fiat 500 can quickly and conveniently store mobile devices and travel gear. In addition, the luggage compartment is spacious, providing a maximum of 30.1 cubic feet of gear. To load in all of the gear easier, designers maximized the tailgate width and kept the trunk lift-over height low.

The Fiat 500's rear seat is designed to be comfortable for two adults and delivers the same high-quality comfort and craftsmanship as the driver and front-passenger seat. To highlight the fact that the car is roomy, the rear passengers' upper seatbacks are raised and bolstered for added back support. To keep everything organized, a new center floor console features larger cupholders and a cubby for small items and houses the 12-volt power outlet.

MODELS & PERSONALIZATION

New Fiat 500 Pop, Sport and Lounge models
The new 2012 Fiat 500 offers three exciting models infused with style, technology and convenience features to make life on the go more personalized and comforting.

"Loaded with Italian style, the 2012 Fiat 500 Pop, Sport and Lounge models provide customers with the perfect blend of emotional design, rational appeal, and a high level of standard features and personalization options," said Laura Soave, Head of Fiat Brand North America. "And with so many original ways to personalize every Fiat 500, our customers' individuality will be recognized wherever they go."
 

• Fiat 500 Pop
  Base MSRP: $15,500 Manual 5 Speed. /  $16,500 Automatic 6 Speed.
  Designed for the individual who wants Italian style, efficiency and personalization options, the new 2012 Fiat 500 Pop includes a manual transmission, 15-inch steel wheels with chrome-accented wheel covers and all-season tires, seven standard air bags, air conditioning, AM/FM/CD/MP3 radio with auxiliary audio input, power windows, power door locks, power heated mirrors, speed control and reconfigurable Electronic Vehicle Information Center (EVIC) with trip computer, miles-to-empty, average fuel economy and tire-pressure monitoring display (TPM).
   
• Fiat 500 Sport
  Base MSRP: $17,500 Manual 5 Speed.  / $18,500 Automatic 6 Speed.
  For the driving enthusiast who demands Italian style with sport-tuned suspension and more convenience features, the new 2012 Fiat 500 Sport model encompasses modified springs, shock tuning, steering calibration and exhaust tuning to deliver a more firm ride and responsive handling.
  The Sport model also includes a manual transmission and (in addition to the Fiat 500 Pop features) distinctively styled front and rear fascias with larger 'honeycomb' grilles and flared aerodynamic treatment.
  
  Between its unique 16-inch aluminum wheels with Mineral Gray painted pockets and all-season tires, the Fiat 500 Sport incorporates new bodyside sill cladding and a liftgate-mounted roof spoiler for a sporty appearance. Completing this athletic vehicle's design theme are Performance Red painted brake calipers attached to a sport-tuned suspension, chromed exhaust tip and fog lamps. Inside, the new Fiat 500 Sport features unique sport-styled seating in a Gray/Black interior environment, a BOSE® Energy Efficient Series audio system with six premium speakers and subwoofer, leather-wrapped steering wheel with audio controls, BLUE&ME™ Handsfree Communication technology with USB port, eco:Drive™ Application and iPod control capability.
   
• Fiat 500 Lounge
  Base MSRP: $19,500 Automatic 6 Speed.
  Tailored for individuals who want their Fiat 500 to reflect their fashion-oriented lifestyles, the new 2012 Fiat 500 Lounge model features premium amenities (in addition to the Fiat 500 Pop features) including the all-new six-speed automatic transmission with driver-selectable gear changes, front- and rear-fascia chromed accents, chrome mirror caps, fog lamps, fixed glass roof, 15-inch aluminum wheels with all-season tires, premium cloth seats, leather-wrapped steering wheel with audio controls, SIRIUS Satellite Radio, BOSE® Energy Efficient Series audio system with six premium speakers and subwoofer, security alarm, BLUE&ME Handsfree Communication technology with USB port, eco:Drive Application and iPod control capability.
   

Unique style and personalization options
With 14 paint colors available in metallic, non-metallic and premium tri-coat pearl finishes, every new 2012 Fiat 500 will be distinct. In addition, the interior is available in two interior environments (Black or Ivory) with 14 unique seat color and material combinations for an individualized look.

A full line of authentic Fiat 500 accessories by Mopar® will offer customers even more personalization possibilities at their local Fiat dealership, including unique striping packages, exterior and interior styling accessories and authentic Fiat-styled merchandise.

WARRANTY

Taking care of the new family members
All 2012 Fiat 500 models will come with a standard four-year/50,000-mile bumper-to-bumper warranty and four years of unlimited roadside assistance. In addition, the new Fiat 500 includes a three-year/36,000-mile maintenance program that includes wear-and-tear items and trip-interruption reimbursement.

SAFETY

State-of-the-art connectivity combined with heritage of top international safety ratings and more than 35 safety and security features keep passengers of the new 2012 Fiat 500 connected, comfortable and secure. In Europe, the Fiat 500 was the first A-segment vehicle to achieve a 5-star Euro NCAP (New Car Assessment Program) adult occupant protection rating.

Seven standard air bags and reactive head restraints
The new 2012 Fiat 500 features an all-new air bag system to offer unique protection for its passengers to meet all U.S. regulatory requirements. Its seven standard air bags include: driver and front-passenger advanced multi-stage air bags, driver's knee air bag, full-length side-curtain air bags and standard seat-mounted side pelvic-thorax air bags, all to offer enhanced occupant protection to all occupants in the event of a collision.

Reactive head restraints, which activate during a rear impact, are another innovation helping minimize injuries by reducing the gap between the head restraint and the passenger's head.

Innovative TomTom® Navigation with BLUE&ME™ Handsfree Communication technology
Developed as a collaboration between Fiat and Microsoft, BLUE&ME™ Handsfree Communication technology is an in-vehicle, voice-activated communication system that allows the driver to operate a Bluetooth®-compatible phone while keeping his or her hands on the wheel and eyes on the road. Using a series of voice commands, the driver can place phone calls, access the phone's address book or listen to MP3s. BLUE&ME Handsfree Communication technology supports most mobile phones with Bluetooth technology.

With the available TomTom® Navigation with BLUE&ME Handsfree Communication technology, the system integrates an innovative 4.3-inch TomTom hand-held navigation unit that docks on top of the new 2012 Fiat 500's instrument panel. With its large touchscreen display, simple map displays with available real-time traffic, weather and more than 7 million points of interests, TomTom navigation with BLUE&ME Handsfree Communication technology is intuitive for the driver to use. And with its direct integration into the Fiat 500's interior system, the driver is able to use steering-wheel-mounted controls to make operation even easier.

Thanks to its portable design, the TomTom Navigation system allows passengers of the Fiat 500 to remove the hand-held device from the vehicle and use it as a guide for walking tours or finding their way back to the vehicle.


Upgraded Electronic Stability Control (ESC)
The new Fiat 500 features standard electronic stability control (ESC) for improved braking performance in wet or panic conditions.

Behind the scenes, the ESC system is ready to intervene by integrating key chassis control systems including electronic brake-force distribution (EBD), anti-lock brake system (ABS) and traction control systems (TCS) to control all four wheels in response to yaw and steering input.

In effect, ESC determines the driver's intentions and adjusts the vehicle's dynamic forces to maintain the driver's intended course. Should the driver exceed the performance limits of the road surface – such that the vehicle starts to oversteer or understeer – ESC instantly analyzes input from the wheel sensors and corrects the pending loss of control by applying any one, several or all of the system's brakes.

More than 35 available safety and security features
The following is a list of the new 2012 Fiat 500's more than 35 available safety and security features which include:

Active turn signals: Turn signal flashes three times when stalk is depressed for 1 second to indicate a lane change (standard)

Advanced multi-stage air bags: Inflates with a force appropriate to the severity of the impact. In addition, Fiat 500's unique driver's air bag design includes tethers to shape the air bag. The passenger airbag has a unique air bag venting system, allowing one vent of the air bag to remain open while the air bag is fully inflating. A secondary vent is actuated as the passenger contacts the air bag at the end of a crash event, offering protection of passengers of all sizes All-speed traction control: Helps to keep driving wheels from spinning during acceleration from a stop or during all speeds by applying individual brakes alone or in combination with engine torque limitation to prevent wheel slip

Anti-lock brake system (ABS): Senses and prevents wheel lockup, offering improved steering control under extreme braking and/or slippery conditions (standard)

Auto-dimming rearview mirror: Detects and reduces glare from rearward headlamps without driver intervention

BeltAlert: Activates a chime and/or illuminates an icon in the instrument cluster to remind the driver and front passenger to buckle up if the Fiat 500 is driven without belted front-seat occupants (standard)

Bi-halogen projector headlamps: Provides wider, more focused light spread and improves forward visibility at night (standard)

BLUE&ME™ Handsfree Communication technology: Provides an in-vehicle, voice-activated communication system that allows the driver to operate a Bluetooth compatible phone while keeping his or her hands on the wheel and eyes on the road. Using a series of voice commands, the driver can place phone calls, access the phone's address book or listen to MP3s

Brake Assist: In an emergency brake situation, the system applies maximum braking power, minimizing the stopping distance (standard)

Brake Override: When a disagreement exists between the throttle and the brake, the brake signal causes the engine controller to reduce engine power, allowing the operator to stop the Fiat 500 (standard)

Brake/Park Interlock: Prevents a Fiat 500 with six-speed automatic transmission from being shifted out of Park unless the brake pedal is applied (standard)

Brake-traction control system (BTCS): Helps to keep driving wheels from spinning during acceleration from a stop or during slow speeds by applying individual brakes to the slipping wheel(s) (standard)

Child seat anchor system: LATCH (Lower Anchors and Tethers for CHildren) is designed to ease installation of compatible aftermarket child seats (standard)

Constant-force Retractors (CFR): Regulates the force exerted on the occupant by the seat belt and then gradually releases seat-belt webbing in a controlled manner. The system features a digressive load limiter for the driver and adaptive load limiter for the front-passenger (standard)

Crumple zones: Designed to deform during an accident in order to absorb energy from an impact which decreases transfer of that energy to occupants (standard)

Daytime running lamps (DRL): Provides additional forward illumination for improved vehicle awareness

Electronic stability control (ESC): Enhances driver control and helps maintain directional stability under all conditions. Provides the benefit in critical driving situations, such as turns, and is valuable when driving on mixed-surface conditions, including snow, ice or gravel. If there is a discernible difference between driver input through the steering wheel and the Fiat 500's path, ESC applies selective braking and throttle input to guide the vehicle back on to the driver's intended path (standard)

Energy management system: Three front load paths designed from high-strength steel manage vehicle crush and minimize cabin intrusion (standard)

Express down windows: One-touch powered express down window button located on the center console (standard)

Full-length side-curtain air bags: Extends protection to all outboard front- and rear-seat passengers. Each side air bag has its own impact sensors that autonomously trigger the air bag on the side where an impact occurs. This type of air bag is housed in the headliner just above the side windows (standard)

Head restraints: Includes all seating positions (standard)

Hill-start Assist (HSA): Assists drivers when starting a vehicle from a stop on a hill by maintaining the level of brake pressure applied for a short period of time after a driver's foot is removed from the brake pedal If throttle is not applied within a short period of time after the driver's foot is removed from the brake pedal, brake pressure will be released (standard)

Intelligent battery sensor (IBS): Continually measures the flow of current into and out of the battery. If the battery is running low, the system intelligently shuts off less critical electrical systems to help prevent a customer being stranded due to a low or depleted battery. When IBS conducts load shedding, an icon appears in the cluster display (standard)

Knee air bag (driver's side): Located below the instrument panel, air bag deploys when the driver's air bag deploys and is designed to properly position the occupant during impact and offer additional lower leg protection

Occupant restraint controller (ORC): Detects an impact and determines whether a crash is severe enough to trigger air bag deployment and whether the primary or secondary stage inflation is sufficient. In addition the controller detects side impacts and determines whether the rail-curtain and side seat-mounted (pelvic-thorax protection) airbags should deploy. Engagement of front seat belt pretensioners are also managed through the controller (standard)

ParkSense® rear park assist system: Assists at low speeds in reverse to detect stationary objects. Consists of audible warnings for the driver and has a display in the instrument cluster's Electronic Vehicle Information Center (EVIC)

Reactive head restraints: Activates in the event of a rear collision. Restraints are designed to reduce injuries by minimizing the gap between the driver and front-passenger head restraint and the passenger's head (standard)

Remote keyless entry: Locks and unlocks doors and turns on interior lamps. If the vehicle is equipped with the optional security alarm, the remote also arms and disarms that system (standard)

Safety cage body structure: Protects occupants by managing and controlling energy in the event of an impact (standard)

Seat belt pretensioners: During a collision, impact sensors initiate front seat belt pretensioners to remove slack in the seat belt system, thereby reducing the forward movement of the occupant's head and torso (standard)

Sentry Key® engine immobilizer: Uses a key fob that has an embedded transponder with a preprogrammed security code to shut off the engine after a few seconds and discourage vehicle theft (standard)

Seat-mounted side pelvic-thorax air bags: Provide enhanced protection to the driver and front outboard passenger in certain impacts. Each side air bag has its own impact sensors that autonomously trigger the air bag on the side where an impact occurs. Standard side air bags are housed within the outboard side of each front seat (standard)

Side-curtain air bags: Provide enhanced protection to all outboard occupants (standard)

Side guard door beams: Provide occupant protection during a side impact (standard)

Three-point seat belts: Front seating positions and all rear seating positions have lap and shoulder belts (standard)

Tilt steering column: Allows steering column to achieve a safe and comfortable driving position (standard)

Tire-pressure monitoring (TPM): Informs driver when tire pressure is too low. Pressure-sensor modules within the valve stems of all four road wheels send continuous radio-frequency signals to a receiver and the system. Individual tire pressure can be displayed in the EVIC (standard)

TomTom® Navigation with BLUE&ME™ Handsfree Communication technology: This innovative navigation system adds a 4.3-inch touchscreen TomTom hand-held navigation unit to the standard BLUE&ME Handsfree communication system. The system features an instrument panel docking system for added driver convenience, real-time traffic, real-time weather updates and more than 7 million points of interests '

Vehicle theft security alarm: Deters vandalism and theft, frequently lowering insurance premiums. System protects the vehicle from theft by monitoring door-ajar switches and the ignition circuit for unauthorized entry

MANUFACTURING

Chrysler Group LLC Modifies Toluca (Mexico) Assembly Plant for Production of the All-new 2012 Fiat 500

• Plant implements new processes and procedures throughout to ensure new Fiat 500 meets or exceeds customer expectations
• More than 2,000 workers trained in World Class Manufacturing (WCM)
• Close to 80 percent of employee suggestions implemented to improve processes

After nearly 16 months of preparation, Chrysler Group LLC's Toluca (Mexico) Assembly Plant is ready for production of the new 2012 Fiat 500.

Chrysler Group announced that it would produce the Fiat 500 in Toluca in August 2009, taking the place of the Chrysler PT Cruiser which ended production after 10 years in June 2010. The Fiat 500 will share the line with the new 2011 Dodge Journey.

In anticipation of the launch of the new Fiat 500, the Toluca Assembly Plant, which has been producing Chrysler vehicles since 1968, went through a significant transformation as part of World Class Manufacturing (WCM), an extensive and thorough process to restore all Chrysler Group facilities to their original and maximum functionality.

World Class Manufacturing (WCM) Takes Hold
What makes WCM different is that it fully engages employees in eliminating waste and empowers them to take ownership of the process.

For Toluca, the first step in ensuring the success of WCM meant putting everyone through training. More than 2,600 employees participated in more than 25,000 hours of training focused on principles of WCM that could immediately help the employee identify and attack waste and losses on the line. Additionally, employees have completed more than 50,000 hours of training on the new equipment installed at the plant.

With the implementation of WCM, employees felt empowered to offer nearly 25,000 suggestions on improvements that could be made throughout the plant, of which 78 percent were implemented.

Toluca Assembly Plant prepares itself for the new Fiat 500
The plant implemented significant changes in all areas of the plant, starting from stamping, through to the body shop, to paint, then final assembly.

In the stamping plant, the company invested more than $44 million to develop 110 new dies (22 sets), for different body parts for the new 2012 Fiat 500.

The plant also installed two new washer machines – one at the blanking press line for the inner and outer parts, and one at the transfer press line for the outer stamping parts – which ensure the elimination of 99 percent of the impurities that could affect the quality of the stampings.

In the body shop, the plant installed five new automated closure lines, including an innovative new process which uses dies for seaming the outer edges of the liftgate, hood, right and left doors called a hemming table-top system. This new system provides for maximum flexibility for the production of more than one vehicle on the closure lines. In addition, a new system for a sealant cure process assures the body applies to the hood, tailgate, and right and left door.

The paint shop was also transformed in order to ensure that the highest quality Fiat 500 rolls off the assembly. As a requirement for production of the Fiat 500, the plant installed a new, fully automated "PVC" sealant application system, a completely new process for Chrysler Group manufacturing. The application system guarantees that no water leaks into the vehicle's cabin and reduces noise.

Because customers can personalize their vehicles with 14 unique exterior paint colors, the Toluca Assembly Plant needed a system to manage paint color changes quickly and with minimal waste. Chrysler came up with an innovative process involving two new paint systems for exterior color management.

Toluca Assembly Plant also installed new equipment for the application of urethane during power sunroof and fixed-glass roof mounting for the new 2012 Fiat 500.

To meet Fiat specifications, the plant installed new torque tooling on the assembly line to avoid any noise or vibration that might be caused by a loose nut or screw.

Another innovative quality control device adopted from the Fiat Group Automobiles (FGA) is the "suspension exerciser," which is assures the suspension settles correctly before the vehicle passes through the wheel alignment process.

Because the new 2012 Fiat 500 will be exported to South American markets with a flex-fuel option, the plant installed new storage and dispensing equipment for ethanol fuel management. To meet Brazilian market requirements, the Toluca Assembly Plant integrated a new crystal-laser beam Vehicle Identification Number (VIN) marker.

Attention to Quality Reaches New Levels
With a renewed focus on quality, Toluca has implemented three different programs to verify the build quality of every new 2012 Fiat 500 that leaves the plant.

The first is Presigi, a process adopted from FGA that consists of a 32-mile course designed with various road conditions to simulate customer driving conditions and focus on the dynamic quality of the new Fiat 500. Second, technical experts at Toluca Assembly Plant's Technical Vehicle Verification Center evaluate wheel alignment, headlamp alignment and appearance. And lastly, a state-of-the-art Metrology Center focuses on dimensional measurements to assure the highest quality fit and finishes.

Fiat 500 Electric Vehicle for the United States

• New Fiat 500EV demonstrates benefits of Chrysler Group and Fiat Group alliance
• Zero-emission Fiat 500EV provides an environmentally friendly, clean, quiet driving experience freeing customers from escalating fuel costs and costly oil changes

Chrysler Group LLC announced its plans to engineer and produce a pure electric vehicle using the Fiat 500 platform. Shown at the 2010 North American International Auto Show in Detroit, the Fiat 500EV demonstrates the immediate benefits of the alliance between Chrysler Group and the Fiat Group as well as the speed at which the two companies can work together on advanced vehicle programs.

"The alliance with Fiat presented new opportunities to merge Chrysler Group engineering knowledge with new platforms and the Fiat 500EV is an outstanding example of our efforts," said Scott Kunselman, Senior Vice President Engineering—Chrysler Group LLC. "The Fiat 500 is a small, lightweight platform perfect for integrating electric-vehicle technology."

The Fiat 500EV powertrain is comprised of three main systems; high power electric powertrain module, advance lithium ion battery, and an EV control unit to manage power flows. Beginning in 2012, Chrysler Group will manufacture the Fiat 500EV for the United States market. All powertrain engineering and vehicle development will take place at Chrysler Group headquarters in Auburn Hills, Mich. Pricing will be announced closer to launch, but will be competitive with similar electric vehicles in the market.

Chrysler Group is the vehicle electrification center of competence for both Chrysler Group and Fiat Group. The company is exploring ways to promote zero-emission transportation and the development of an electric-vehicle charging infrastructure through partnerships to be announced in the future.

Last year Chrysler Group announced the company's intention to build the Fiat 500 with a combustion engine for North America. The vehicle will debut in late 2010.

Chrysler Group's alliance with Fiat Group brings new platforms and technologies that allow the company to create an improved long-term product strategy with greater fuel efficiency and reduced emissions. Chrysler Group's five-year plan has an uncompromising product schedule, including a progressive vehicle electrification strategy.