Chrysler has begun production of the long-awaited PT Cruiser Convertible at its Toluca (Mexico) assembly plant, the same factory that produces the five-door tin-top Cruiser.
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Chrysler has spent about approximately $US45 million on tooling and equipment at Toluca to build the new convertible. The company also implemented a cross-functional launch team that was able to maintain production of the Chrysler PT Cruiser five-door while managing the equipment changeover for the launch. The result was a rolling launch with no loss of production.
During the rolling launch, pre-production Convertibles were built and tested on the same assembly line that makes the five-door, steadily ramping up while not compromising existing production at the plant. The launch team was able to verify the quality of the equipment and new manufacturing processes seamlessly, enabling a faster ramp-up without compromising quality.
“From the ongoing production of PT Cruiser to the rolling changeover, we achieved positive gains in productivity and quality, without missing a day of production,” said Roberto Gutierrez, vice president of Mexico Manufacturing Operations at Chrysler.
A number of changes were implemented at Toluca Assembly in preparation for PT Cruiser Convertible production, and in order to add greater plant flexibility. New robotic equipment was installed in the body shop’s welding operations for improved precision and efficiency. The trim, chassis and final assembly area was expanded to build both five-door and convertible models.
A new dedicated line was installed for the convertible’s underbody process. A combination of robotic and employee-manned work stations weld the underbody, engine compartment and body side systems. This arrangement reduces floor space requirements for a more flexible and efficient plant, resulting in the capacity to build additional body lines within the plant at a minimum investment.
Convertible assemblers use a newly installed ergonomic assist arm to position the top module for installation to the vehicle. A fixture then aligns the top to the rear quarter panels, while fasteners lock the top into the proper alignment. Using the setting fixture assures a repeatable fit to the vehicle, which helps achieve the optimal fit and finish on the final vehicle.
The PT Cruiser is now sold in over 90 countries.
