Zero down-time in launching Wrangler Unlimited

Building the 2004 1/2 Jeep(R) Wrangler Unlimited is more complex than simply stretching the wheelbase. Converting the manufacturing facilities -- including the oldest operating automotive plant in the country -- into modern, flexible production facilities stretched the ingenuity of Chrysler Group workers.

The new Wrangler Unlimited offers double the cargo capacity and is 15 inches longer than the original Wrangler. The Toledo (Ohio) South Assembly Plant encompasses the Stickney Avenue Plant, built in 1942, and the Parkway Annex, which began life as a bicycle plant in 1904. Stamping, body and paint facilities are located at Parkway; trim, chassis and final assembly take place at Stickney.

"For many manufacturers, it might be easier and more desirable to start with a clean slate and build a greenfield site," said Frank Ewasyshyn, Chrysler Group Executive Vice President - Manufacturing. "But Toledo is the home of the Jeep Wrangler and the loyal workforce provided the ingenuity and commitment needed to adopt the latest manufacturing technologies into a century-old manufacturing site."

From Old to New - Adopting Flexible Technologies and Processes

Toledo South Assembly Plant began the conversion to accommodate the longer wheelbase Wrangler in July 2003 during the regularly scheduled plant shutdown to achieve a rolling changeover. A rolling changeover enables a plant to continue existing vehicle production while adapting equipment and manufacturing processes for a new vehicle launch.

Another key enabler for the smooth changeover was the early introduction of flexible manufacturing principles at Toledo South. In 1998, the plant became the company's "guinea pig" by developing small teams, which later became standard operating procedure at Toledo (Ohio) North Assembly Plant, where the Jeep Liberty is built.

"Team-based operating principles and rolling launches are key to becoming competitive in the marketplace," explained Byron Green, Chrysler Group Vice President of Truck and Activity Vehicle Assembly Operations. "We put a plan in place for the Unlimited launch and we were able to achieve a zero-loss of production during the launch. Plus, the quality level was such that we were able to ship the vehicles to the dealers three weeks ahead of the launch plan. This was one of the best launches in the company's history."

Chrysler Group has been a leader in virtual manufacturing. Virtual tools were critical in finding innovative ways to fit 21st century tooling and robots into a facility with low ceilings, narrow passages and many concrete ceiling supports that are common in older buildings.