Assembly - November 2008 - (Page 37) Trucks such as the Chevrolet Silverado (left) and the Hummer H2 (right) use seats made by Advanced Assembly LLC. LLC (South Bend, IN) and General Motors Corp. (GM, Detroit) truck plants in Mishawaka, IN, and Roanoke, IN, that assemble vehicles such as the Chevrolet Silverado, GMC Sierra and Hummer H2. The company recently took several steps to improve productivity and shorten time to market by investing in new assembly tools and state-of-theart technology. For instance, Advanced Assembly has installed five visionguided robots over the last two years that have saved the company more than $690,000. It also uses automated guided vehicles to deliver parts to the assembly line, in addition to DC electric fastening tools and a modular twin-track conveyor system equipped with radio frequency identification (RFID) pallet tracking. Those investments have helped the plant increase operating efficiency while reducing labor and overhead costs. Last year, Advanced Assembly exceeded its goal for margin improvement by 185 percent, and the company is on track to exceed that goal by more than 150 percent in 2008. Other tools the plant uses to improve productivity include: Proximity sensors that electronically verify the bolt or nut that’s being torqued. Laser and vision systems that electronically verify seat-specific content. A wireless scanning system that captures incoming raw material for comparison with electronic shipping documents. “We also interrogate multiple trigger points in our customer’s preassembly process,” says David Berkes, quality manager. “These triggers drive our build file, allowing us to assemble products on a just-in-time basis and sequence delivery of seats within three hours of point of use. “Our delivery trailers are fully automated and equipped with an internal conveyor system that allows for quick, error-free delivery,” adds Berkes. “In addition, each delivery trailer employs a GPS tracking systems that allows us to receive immediate information on truck location and time of arrival at our customer. Our automated storage and retrieval system is dynamic; it adjusts to our customer mix swings, allowing for efficient storage of approximately six hours of finished product.” Operators have played a key role in the success of the TS 16949 and ISO 14001-certified plant. For instance, they participate in continuous improvement workshops and selfdirected work teams that address issues relating to productivity, quality and safety on the plant floor. “Our associates play an active role in the successful implementation of new assembly strategies,” says Berkes. Kenworth Chillicothe Next time you drive on a highway and pass by a big truck, briefly look in your rearview mirror. Chances are you’ll see a big red and white KW logo on the front grill. Because of its product innovation and reliability, Kenworth Truck Co. (Kirkland, WA) is recognized as the industry leader for Class 8 trucks. The company builds two of its most popular vehicles, the T660 and the T2000, at a 35-year-old plant in Chillicothe, OH. Although the heavy-duty truck market declined substantially in 2007 compared to the previous year, major capital investments were made in the plant to achieve lean processes and significantly increase capacity. The expanded use of robotics, logistics and RFID technology has streamlined operations and improved productivity and efficiency by 20 percent. For example, a new automated robotic fuel tank welding cell uses state-of-the-art technology. “The benefits are improved quality, reduced damage, reduced cycle times and lower manufacturing costs,” says Joe Zitzelberger, director of manufacturing development. Personal computers, scanning devices and handheld computers are connected wirelessly plantwide, supporting mobile applications and flexible work area configuration. Operators also use DC electric fastening tools to tighten www.assemblymag.com November 2008 / ASSE M B LY 37 http://www.assemblymag.com
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