Chrysler has begun production of the 2007 Dodge Nitro at its Toledo North Assembly Plant which has built the Jeep Liberty/Cherokee since 2001.
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This is the latest model assembled under the group’s expanding flexible manufacturing strategy (FMS) that puts new vehicles on sale more quickly and allows plants to manufacture multiple products on one line.
Toledo North was extensively retooled to manage the complexity of building two different models on one line. The Nitro investment of $US600m included multiple plant upgrades, improving quality, productivity and worker ergonomics. Over 160,000 square feet were added to the plant floor to enhance body and assembly processes.
The retooling is part of $3.9bn spent on manufacturing capabilities there that include the original $1.2bn to build Toledo North (opened in 2001) and $2.1bn for Toledo Supplier Park, home of the 2007 Jeep Wrangler and Wrangler Unlimited four door.
“Toledo traditionally has been the home of the iconic Jeep Wrangler,” said Chrysler’s head of truck and activity vehicle assembly, Byron Green.
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By GlobalData“But with two new, modern plants and four products, Toledo has become an epicenter of Chrysler Group’s manufacturing capabilities.”
Core to the new manufacturing process is a body shop comprised of 150 new robots instead of the vehicle-specific heavy tooling that was previously used. The door, hood and liftgate assembly system is new, as are the side aperture assembly systems. Only the robots’ end effectors, 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. TNAP is flexible enough to vary production mix between two products anywhere from 0 to 100% of each model. A third model can also be piloted at the same time, helping reduce the time needed to make new model changeovers.
New methods of material flow are being implemented to manage the complexity of two models being built on one assembly line. An inbound parts sequencing centre is housed in the adjoining Stickney complex and manages more than 1,800 different parts that are used in the Nitro, Liberty and Wrangler models’ build process in the two assembly plants.
In addition to sequencing, this centre provides parts metering, kitting and container management to both assembly plants.
A significant portion of the TNAP facility is fork truck-free as dollies will provide materials to production areas, improving both employee safety and productivity measurements.
A new workplace organisational model, coined Smart Manufacturing, is increasing the flexibility of the TNAP workforce, while fostering greater creativity and innovation from plant employees. This model is being implemented throughout the Chrysler manufacturing organisation. In addition to extensive training, the new model lets employees design their own work stations, providing a better work environment for employees and giving increased support to assembly line workers.
The Nitro is the first mid-size SUV for the Dodge brand.
