Chrysler shifting to Japanese method of 'flexible manufacturing'

Sept. 1, 2005
Daimler Chrysler AG's Chrysler Group is revamping its manufacturing process in the hopes of saving billions of dollars in development and production costs.

The Dodge Caliber concept car, a version of which will be built at Belvidere, Ill.


For nearly a decade, Japanese automakers including Toyota Motor Corp. and Honda Motor Co. have been using "flexible manufacturing" to build three or more different models in a single plant. At some plants in Japan, Toyota and Honda produce as many as six different models per assembly line. Now, rising costs are forcing Chrysler, GM, and Ford to adopt similar methods.

Key to Chrysler's new process is a new generation of stronger, less expensive robots that can carry, hold and pass on large structural auto parts such as side panels, roofs and underbodies. Industry observers say robots are now more like commodities that can be assembled with off-the-shelf parts, including stronger electric motors that can lift heavier loads. Ten years ago, a robot that could lift a 330-lb part cost about $80,000; today one that lifts 495-lb parts costs about $30,000.

These new robots should allow Chrysler to do away with the stationary equipment used to hold metal parts while they are being welded—equipment that often costs hundreds of thousands of dollars.

The process will be initially used this fall at Chrysler's plant in Belvidere, Ill. The point of the retooling is to have plants operate at close to maximum capacity, a big factor in increasing profitability.

The fragmentation of the U.S. vehicle market makes it difficult to sell all of a typical plant's production (roughly 200,000 to 240,000 vehicles a year) when all those vehicles are the same model. The new approach would reduce output of a single model to 75,000 to 100,000 per plant. The Belvidere plant will use flexible manufacturing to build a new compact hatchback and two small Jeeps. Next, Chrysler plans to install the process in its Sterling Heights, Mich. plant, eventually expanding it to 12 other North American plants.

Sponsored Recommendations

Diaphragm Pump Technology Drives Industrial Washers

Jan. 23, 2025
Discover high-performance pumps and systems built to handle various gases, liquids, and chemicals with precision.

Harmonic Drive Actuators with Integrated Drive Technology

Jan. 17, 2025
Discover the future of motion control.In this video, we explore how integrated drive technology (IDT) from Harmonic Drive is revolutionizing the precision mo...

7 factors to Consider When Choosing the Right Gear Technology

Jan. 17, 2025
Choosing a drive involves several design factors that depend greatly on the task at hand. This top 7 list will guide you, whether your task requires precise and exact movements...

What are the Benefits of Actuators with Integrated Servo Drives?

Jan. 17, 2025
Actuators with Integrated Servo Drive Technology (IDT) simplify cable management, control hardware, and commissioning while achieving outstanding performance in a compact size...

Voice your opinion!

To join the conversation, and become an exclusive member of Machine Design, create an account today!