Chrysler Group has started the process of redesigning its auto assembly plants to increase productivity. The biggest changes have taken place on the assembly line — increasing efficiency, decreasing waste and making working conditions safer for employees.
Chrysler Group has enjoyed great success in recent years, thanks to consistently high sales of the Ram 1500. In order to cope with the demand, Chrysler has redesigned its Warren Truck Assembly Plant to boost production.
Beginning in 2013, Chrysler began making changes to the assembly line at the Warren Truck Assembly Plant. According to Curt Towne, the plant manager, the aim of the redesign was to rethink the plant's processes while keeping the focus on the quality of the vehicles produced and on the experience of the end customer. He stated that he considers this goal to have been achieved.
A key part of the assembly line redesign was the introduction of a Work Place Integration process. This process involves reviewing every workstation along the assembly line to identify best practices. One change that was made as part of this process was to change how materials and parts needed on the assembly line are stored. Whereas they were once located to the side of the assembly line, parts are now placed in large carriers, which makes them more accessible to assembly line operators. The amount of time that operators spend walking to collect parts that they need has been significantly reduced, leading to an increase in the number of trucks produced each day.
The Chrysler assembly plant redesign was carried out according to the World Class Manufacturing methodology. WCM methodology focuses on improving logistics, reducing waste, product quality and plant safety.
A key WCM principle is engagement with assembly line employees. Operators at the plant offered suggestions about how to improve their work stations. As a result of this engagement, more than 300 parts were moved or redesigned to make the assembly line more ergonomic and reduce the risk of operator injury. Once the plant had been redesigned, nearly two-thirds of plant operators were trained in new assembly line processes to improve productivity.
As a result of the Warren Truck Assembly Plant redesign, the plant now produces an extra 100 vehicles every day. This helps Chrysler to better meet demand from consumers. The company's products have been selling well in recent years, particularly the Ram 1500, which is produced at the Warren Truck Plant. The auto industry in general is experiencing a strong recovery, with higher consumer demand leading to steadily rising sales figures.
Chrysler's redesign of the assembly line at the Warren Truck Assembly Plant has allowed the company to significantly increase production of the Ram 1500. This could lead to greater profits for Chrysler in 2014 and beyond.
Photo courtesy of amateur photography by michel at Flickr.com
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