The Chrysler Group today
officially launched production of the all-new 2007 Dodge Nitro at its
Toledo North Assembly Plant (TNAP) that has been producing the Jeep®
Liberty since 2001. The Dodge Nitro represents Chrysler Group’s
expanding Flexible Manufacturing Strategy (FMS) allowing the Company to
bring its new vehicles to market more quickly and the assembly plants
the ability to manufacture multiple products on one assembly line.
The Toledo North Plant was extensively retooled
to manage the complexity of building two different models on one
production line. The Dodge Nitro program investment of $600 million
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 of Toledo
North is part of $3.9 billion spent on Toledo manufacturing
capabilities that include an original $1.2 billion to build Toledo
North (opening in 2001) and $2.1 billion for Chrysler’s Toledo Supplier
Park, home of the all-new 2007 Jeep Wrangler and Wrangler Unlimited
four door.
“Toledo traditionally has been the home of the
iconic Jeep Wrangler,” said Byron Green, Vice President – Truck and
Activity Vehicle Assembly. "But with two new, modern plants and four
products, Toledo has become an epicenter of Chrysler Group’s
manufacturing capabilities. The innovative manufacturing changes
currently taking place in Toledo have allowed TNAP to manufacture
multiple products on one production line, giving the Company the
ability to quickly adapt vehicle production to meet customer demand."
Flexible Manufacturing Strategy (FMS)
Chrysler Group's Flexible Manufacturing Strategy allows the Company to
produce a higher quality product, faster, for lower cost. FMS is also a
key enabler in the company’s plan to launch 10 all-new vehicles in
2006, the most in Chrysler Group's history. In order to balance
production with demand, the FMS approach allows the company to
efficiently build lower-volume vehicles that take advantage of market
niche, and to quickly shift production volumes between different models
within a single plant or among multiple plants.
FMS is being implemented product by product and plant by plant
across the Chrysler Group. New investment is introducing
state-of-the-art technology to Chrysler Group plants enabling the
company to produce more than one vehicle on a production line and
conduct rolling launches of new models. Additionally, Chrysler Group's
workforce is becoming more flexible with the implementation of team
concepts and an increased emphasis on supporting assembly line
operators.
Robotics
At the core of 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 percent
of each model. A third model can also be piloted — or test-built — at
the same time, helping reduce the time needed to make new-model
changeovers.
Material Flow
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 center is housed in the adjoining Stickney complex and
manages more than 1,800 different parts that are used in the Dodge
Nitro, Jeep Liberty and Toledo Supplier Park's Jeep Wrangler two-door
and Jeep Wrangler Unlimited four-door build process. In addition to
sequencing, this center provides parts metering, kitting and container
management to both Toledo North and Toledo Supplier Park Assembly
Plants. Furthermore, a significant portion of the TNAP facility will be
fork-truck-free as dollies will provide materials to production areas,
improving both employee safety and productivity measurements.
Smart Manufacturing
A new workplace organizational 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 Group's Manufacturing
organization. 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.
"TNAP is proud to be the home of the new Dodge Nitro," said Luis
Rivas, Plant Manager – Toledo North Assembly Plant. "The employees are
pleased to be contributing toward the Company's goal of world-class
operational excellence in 2007."
Dodge Nitro
Dodge brings its “Grab Life by the Horns” attitude to the mid-size
sport-utility vehicle (SUV) segment with the introduction of the
all-new 2007 Dodge Nitro. The five-passenger Nitro features bold,
aggressive styling with performance to match. The Dodge Nitro is
designed and engineered to ignite a segment characterized by bland,
mild-mannered entries. This is the first mid-size SUV for the Dodge
brand and complements its lineup of cars, minivans, trucks, commercial
vehicles and a full-size SUV.
The Dodge Nitro offers all the mid-size SUV must-haves: space,
functionality and flexibility. Nitro’s fold-flat, first-row passenger
seat and second-row seats offer a variety of loading options. Also new
is the LOAD 'N GO™ cargo floor, which slides 18 inches rearward for
easy loading and unloading and holds up to 400 pounds. With optional
heated leather seats, a DVD-based navigation system, cutting-edge
entertainment system options, and a long list of standard safety and
security features, the Dodge Nitro spices up the mid-size SUV recipe.
The 2.1 million square-foot Toledo North Assembly Plant occupies 200
acres and has more than 2,700 employees working two shifts, with the
third shift of approximately 750 employees to begin in the third
quarter. Groundbreaking of Toledo North began in fall 1997.
A third DaimlerChrysler plant is located in nearby Perrysburg,
Ohio. The Toledo Machining Plant opened in 1967 and produces steering
columns and torque converters.
Commitment to the Community
DaimlerChrysler has demonstrated a long-standing commitment to invest
in existing facilities and provide good-paying jobs in urban
environments. By renovating many of its existing facilities,
DaimlerChrysler was a leading corporate investor in urban America
during the 1990s. This decade, the company is continuing the trend in
cities such as Toledo, St. Louis, Detroit and Warren, Mich.
In total, DaimlerChrysler has a significant impact on Toledo and the
State of Ohio, with 7,941 employees statewide generating $465 million
in annual wages and providing more than $26 million in taxable income
to the state.
As a good neighbor and good citizen, Chrysler Group sponsors various
community events through its philanthropic arm, the DaimlerChrysler
Corporation Fund, including the Art Tatum Jazz Heritage Festival,
Toledo Urban League, City's Youth Entrepreneur Program, Toledo Opera,
the Toledo Museum of Art, Valentine Theatre and the Diamante Awards.
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