Chrysler Group's new flexible manufacturing system will enable the company to build the all-new Pacifica on the same line with its segment-leading minivans. This system helps bring new products like Pacifica to market faster, with better quality, less investment and minimal downtime. The company invested $300 million in Windsor Assembly Plant for the all-new product.
The ability to build multiple products on the same line enables the company to build the test prototype vehicles much earlier in the launch phase. Because the same tooling and same processes are employed (rather than a simulated line), the company can better train operators and resolve manufacturing issues much sooner. The result is also better quality.
This flexible manufacturing system was first used in the launch of the all-new 2001 Chrysler Voyager, Town & Country and Dodge Caravan series of minivans in the summer of 2000. Windsor Assembly ramped up to maximum production of about 25,000 of the all-new model in just 25 days, compared to a 110-day industry average for a major changeover of this type.
"Flexibility is more and more becoming the key ingredient in manufacturing," said Tom LaSorda, Chrysler Group Executive Vice President of Manufacturing . "The benefits of building pre-production vehicles on the same line where the production vehicles will be built results in better quality, lower costs, less downtime and minimal production loss. That represents huge savings to the bottom line."