Chrysler has started production of the new Jeep Compass at its Belvidere, Illinois, assembly plant.
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The plant, which was extensively retooled in 2005, has become a flagship for Chrysler group’s adoption of flexible manufacturing.
Production of the Dodge Caliber began at the plant in January, and the Compass, which shares the same platform, is built on the same assembly line. A third model, the Jeep Patriot, is scheduled to be added in autumn.
“Thanks to Belvidere’s ability to build multiple models off one assembly line, we expect the Jeep Compass production to cost significantly less than the initial investment we made in the plant to build the Dodge Caliber,” said Chrysler’s executive vice president of manufacturing, Frank Ewasyshyn.
At the core of the new manufacturing process is a body shop comprised of robots instead of the dedicated tooling that was previously used. Belvidere is Chrysler’s first assembly plant to use a body shop comprised entirely of robotics. Only the robots’ end affectors, or ‘hands’, need to change in order to build the different models. That tool change is done automatically, within the time it takes to cycle from one vehicle to the next.
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By GlobalDataIn addition, the Belvidere plant is flexible enough to vary the production mix between three products anywhere from 0 to 100% of each model. A fourth model can also be piloted, or test-built at the same time, helping reduce the time needed to make new-model changeovers.
The new body shop and other upgrades are part of a US$419m total Belvidere investment announced in 2005.
New methods of material handling are being implemented to manage the complexity of three models being built on one assembly line. The inbound parts sequencing centre manages more than 1,800 different parts that are used in the Jeep Compass and Dodge Caliber build process. In addition to sequencing, this center provides parts metering, kitting and container management to the Belvidere Assembly Plant and delivers complete subassemblies just-in-time to the manufacturing floor.
A tunnel connects the 500,000 square-foot sequencing center to the Belvidere Assembly Plant. This facility, operated by TDS/US — one of Chrysler Group’s largest minority-owned suppliers — represents the highest level of integration within a Chrysler Group plant. TDS/US organises parts, puts them in “kits” for individual work stations and delivers them to the end of a connecting tunnel for Belvidere employees to transport to the manufacturing floor. This process maintains in-plant stocks at optimal levels, minimizes delivery time and reduces costs an estimated 12% a year compared with the previous process.
A new workplace organizational model, coined SMART manufacturing, is increasing the flexibility of the Belvidere workforce, while fostering greater creativity and innovation from plant employees, said Chrysler in a statement. This model is being implemented throughout Chrysler Group’s Manufacturing organisation. In addition to extensive training, the new workplace model lets employees design their own work stations. These changes provide a better work environment for employees and give increased support to assembly line team members.
Chrysler adds 3rd shift at Belvidere
