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Discussion Starter · #101 · (Edited)
Facts & Figures: Detroit Assembly Complex – Mack


Site History:
  • 1916: Michigan Stamping Company, first automotive use for the Mack site
  • 1920: Briggs Manufacturing purchases plant
  • 1953: Chrysler Corporation purchases Briggs Manufacturing, acquires Mack property
  • 1975: Chrysler builds 1 million-square-foot expansion next to the “Old Mack” plant
  • 1982: Chrysler closes Old Mack, sells it to city of Detroit for redevelopment
  • 1982-1989: Old Mack sits idle
  • 1990: City of Detroit and Chrysler begin extensive cleanup of Old Mack site
  • 1995: Old Mack plant leveled and entire site cleaned up
  • 1991-1995: Dodge Viper produced at “New Mack” before it was moved to Conner Avenue Assembly plant
  • 1996: Construction of Mack Engine begins; opens in 1998 to produce V-8 engines
  • 2000: Mack Engine II construction completed; produces V-6 engines
  • 2012: Mack Engine II idled
  • 2019: $1.6 billion investment announced to turn Mack Engine Complex into new assembly site for the all-new, three-row Jeep® Grand Cherokee, next-generation Grand Cherokee and electrified models
Plant Overview:
  • More than 100 years of manufacturing on Mack site
  • First new assembly plant in the city of Detroit in 30 years
  • Investment: $1.6 billion (announced February 2019)
  • New jobs: 3,850; commitment to putting Detroiters first in the application process
    • 2,100 Detroiters have filled the new positions
  • Construction: Began in Q2 2019; completed in less than two years
  • Total floor space: 3 million square feet
  • Acreage: 266
  • Operating pattern: Three shifts, five days per week
  • Employment: ~4,900
  • Total production time: ~36 hours
  • Three main production facilities: Body shop, paint shop and general assembly
  • Logistics: 770 inbound trucks per day; 76 trucks and 95 railcars outbound per day
Body Shop:
  • Building: Formerly Mack Engine II; idled in 2012
  • Floor space: 650,000 square feet
  • Robots: 578
  • Production time: 2 hours
Net Form & Pierce
A net form is created for the Jeep Grand Cherokee L to establish the perfect dimensional environment to hang panels, such as the hood, liftgate, doors and fenders, before the body is pierced. Robots measure the gaps and fits to ensure they are symmetrical. There are 26 robots in the cell.

Near-line Laser Radar
Radar technology is mounted on robots to measure hundreds of preprogrammed surface and alignment points to verify the build process. This 45-minute validation test is performed on a select number of vehicles across all three production shifts and complements the inline measurement system that measures every Jeep Grand Cherokee L coming through the body shop.

Paint Shop:
  • Building: All-new facility
  • Floor space: 800,000 square feet (five floors)
  • Robots: 124
  • Production time: 12 hours
  • Colors: 11
  • Process: Fully automated; 100% robotic spray application
    1. Phosphate E-coat: First layer of corrosion protection
    2. Sealer: 28 robots; ~208 feet of sealer applied per car to prevent leaks, corrosion and wind noise
    3. Primer: 8 robots; provides smooth base layer and enhances paint durability
    4. Base paint coat: 21 robots (10 painting and 11 “opening”)
    5. Clear coat: Final protective coating
    6. Finesse and polish: Identify and remove any imperfections to ensure smooth paint finish
General Assembly:
  • Building: Formerly Mack Engine I; built the Pentastar engine family until December 2019
  • Floor space: 1,000,000 square feet
  • Stages: Trim, Chassis, Final
    • Trim: Installation of sunroof, wiring harness, major electrical, instrument panel and windshield, rear and half glass
    • Chassis: Engine dress; engine and chassis marriage; body and chassis decking; hose and electrical connections; fluid fill and functionality testing
    • Final:Installation of seats, steering wheel, major components; doors hung; wheels and tires; electrical test
      • Final validation: Aligners, headlight aim, rolls, ADAS (Automated Driver Assist System); BSR test track; inline water test; certification line
Buzz, Squeak and Rattle (BSR) Test Track:
  • Completely enclosed
  • Length: 2,000 feet
  • 100% of vehicles tested
  • Total test time: 3 minutes
  • Simulates real-world driving conditions
  • 11 different elements, including pot holes, manhole covers, rumble strips, cobblestones, speed bumps, gravel, Figure 8
BSR Shaker:
  • Additional validation beyond test track
  • Electro servo shaker, first of its kind in North America
  • Test time replicating BSR track: 2 minutes, 40 seconds
  • Additional testing of more aggressive conditions: 3-5 minutes
Inline Water Test:
  • 100% of vehicles tested
  • Total test time: 3 minutes
  • 600 nozzles delivering water at 30 psi
  • Additional validation performed in Nine Position Water Test; simulates different terrain (hills and inclines) and weather conditions

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25,347 Posts
Discussion Starter · #102 ·
Trailer for Detroit Assembly Complex - Mack Documentary

Stellantis will celebrate the launch of the Detroit Assembly Complex - Mack plant and the progress on those commitments with the release of a 15-minute documentary film on July 28, featuring the people instrumental in bringing the project to life and those who have partnered with the Company to bring meaningful change to the city.

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Discussion Starter · #103 ·
Stellantis reinstates mask mandate at local plants

Carson Gerber, Kokomo Tribune, Ind.
Fri, July 30, 2021, 6:20 PM

Carson Gerber, Kokomo Tribune, Ind.
Fri, July 30, 2021, 6:20 PM

Jul. 30—Workers and visitors at the Stellantis plants in Kokomo and Tipton will once again be required to wear masks as the number of new COVID-19 cases rise in the area.
The company said the mandate will take affect Monday and is required for everyone inside the facilities, regardless of a person's vaccination status.
A company spokesperson said the mask mandate is only being reinstated at its Indiana facilities and the Belvidere Assembly Plant in Illinois. The decision was based on CDC data regarding new COVID cases and positivity rates in the area, as well as its own internal data.
According to the Indiana State Department of Health, Tipton County on Friday was at orange status and had a seven-day positivity rate of nearly 19%, which is currently the highest in the state. Howard County was also recently elevated from the blue to yellow status.

"Protecting the health and safety of our Stellantis workforce continues to be our top priority," the company said in a statement. "As COVID cases are once again increasing in communities across the country, we continue to strongly advocate that our employees consider getting vaccinated."
The reinstated mandate comes less than a month after the company lifted the restriction on July 12 following a decision by a virus task force with representatives from Ford, General Motors, Stellantis and the United Auto Workers. The policy change applied to all U.S. auto workers from the three companies.

In June, Stellantis also lifted other COVID precautions at its plants, including taking workers' temperatures and the 10-minute cleaning routine that had been in place for over a year. Staggered shifts also stopped.

A company spokesperson said those measures are not being reinstated at this time.

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Discussion Starter · #104 ·
Stellantis Windsor Assembly Plant Recognized for Energy Reduction
20 August 2021
stellantis Windsor

The Chrysler Pacifica rolls off the final line at the FCA US Windsor Assembly Plant ahead of the previous generation minivan, the Dodge Grand Caravan. The Company spent $744 million to retool the plant to produce the Pacifica. PHOTO Stellantis

The Stellantis Windsor Assembly Plant (WAP) has been recognized by the Association of Energy Engineers (AEE) for the 2021 Canada Region Energy Project of the Year.
The plant’s winning project reduced energy usage in the paint shop by 20,250 gigajoules (GJ) or 8% annually of the topcoat process, the equivalent of the electricity used in 490 homes in one year.
The WAP energy management team was awarded for key process improvements implemented during the topcoat paint application process as part of its “Topcoat Observation Booth Downdraft Optimization” project.
“Our energy management team at the Windsor Assembly Plant has once again risen to the challenge with their dedication and leadership in eliminating energy losses and enhancing eco-friendly efficiencies within our plant and throughout our company overall,” said Jon Desjardins, WAP Plant Manager.
“I’m very proud of their continued efforts in creating a positive and sustainable environmental footprint.”
“I’d like to congratulate Stellantis on their recent Regional AEE Energy Project of the Year award in the Canada Region,” said Melanie Claus, Membership Director of the AEE.
“Identifying top energy losses and developing solutions that can be standardized is a perfect representation of what AEE members are doing to further advance the energy efficiency industry.”
Topcoat Observation Booth Downdraft Optimization
At the Windsor plant, which builds the Chrysler Pacifica, Chrysler Pacifica Hybrid, Chrysler Grand Caravan and Chrysler Voyager (U.S. market) minivans, a new vehicle rolls off the line every 48 seconds.
It takes approximately 27 hours to complete a vehicle, with 8-10 of those hours spent in the paint shop.
A recent onsite study conducted by the plant’s energy management team identified opportunities to reduce energy consumption in the paint shop.
A detailed assessment that began in November 2019 confirmed that the topcoat process was a top source for energy loss in the paint shop.
The energy management team determined that energy could be saved by optimizing the downdraft airflow in the three paint booths.
In the booths, there are 18 air houses that pump in the fresh air and 20 exhaust fans that help create an equilibrium to maintain a steady temperature of 62 degrees Fahrenheit and required downdraft.
The three paint booths are each divided into eight zones.
In the “Observation Zone,” the team optimized the downdraft airflow from the air houses by reducing the rate of fresh air in that zone while maintaining the required airflow and temperature in the other zones.
They were able to do this without compromising the plant’s paint application quality and performance.
For these efforts, the plant is also in the process of receiving an incremental energy rebate on behalf of the Independent Electricity System Operator (IESO) of Ontario and Enbridge Utilities.
Stellantis and the WAP energy management team will be honoured at the AEE Regional Awards Tuesday, Oct. 19, the day prior to the opening of the 2021 AEE World Energy Conference & Expo in New Orleans, Louisiana.

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