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Auto assembly and mfg. logistics #5331362 01/24/20 08:26 PM
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P10crew Offline OP
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I would like to get some assembly plant discussion going.
I have always pondered the amazing amounts of components that must go into the back doors of one of these plants. Although it’s high on my list of things to do when I retire I have not had the opportunity to tour one. Parts like tires, wheels, windows, transmissions and on and on must come to these plants by the train load each day to fulfill the daily needs.
Is there by chance anyone in here that can shed light on this challenging logistics nightmare?

Last edited by P10crew; 01/24/20 08:27 PM.
Re: Auto assembly and mfg. logistics [Re: P10crew] #5331366 01/24/20 08:38 PM
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P10crew Offline OP
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The source I am reading from says GM sold just shy of 1 million trucks last year. Taking duallys out of the equation that’s 5 million tires and rims how many tires can one fit in one train car?

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331373 01/24/20 08:49 PM
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Originally Posted by P10crew
The source I am reading from says GM sold just shy of 1 million trucks last year. Taking duallys out of the equation that’s 5 million tires and rims how many tires can one fit in one train car?

If it's a clown car, a lot.😉

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331376 01/24/20 08:55 PM
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I have worked in manufacturing companies for many years.
For the components that flow to the manufacturing lines at the proper place and time, there are 2 major concepts:
1) Material Requirements Planning aka MRP (based on the Bills of Material); Manufacturing Resource Planning aka MRP2 (adds operations planning).
2) Just in Time aka JIT, which pushes much of the planning back to the vendor.

In reality, companies do all these badly. Especially in complex, custom products.
Materials generally account for 80% or more of Accounts Payable in an manufacturing company.


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Re: Auto assembly and mfg. logistics [Re: P10crew] #5331403 01/24/20 09:31 PM
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I worked on the line at Chrysler Windsor Assy. (Canada) in "body in white" in 1964/65.
We were building a unit every 54 seconds and we did every model from a Valiant 2dr to a Chrysler New Yorker convertible and everything in-between.
We did not build the Imperial in Windsor Ontario at that time.

No two identical vehicles came down the line one after another, they were totally mixed up.
One car was a Barracuda 273, the next car was a valiant 4dr 225, the next was a Fury station wagon 383, the next a Chrysler 4 dr hardtop, we did right and left hand drive etc etc etc ....

Talk about flex manufacturing. Talk about logistics and planning. Talk about a pile of parts !!



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Re: Auto assembly and mfg. logistics [Re: P10crew] #5331409 01/24/20 09:40 PM
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hallstevenson Online Content
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I used to go into Ford's engine plant in Lima OH. It's a large, convoluted complex with multiple buildings built and added on over many decades. Anyway, this facility did have a "main" receiving area where general material came in (including material not used in the final products). It also had dozens of receiving docks all around the building. Just making examples, but say at dock # 1, engine block castings were delivered. At dock # 10, spark plugs were delivered. At dock # 15, coolant and engine oil were delivered. See the concept ?

Another example is Setex in St Mary's OH. They made .... seats and exclusively for Honda's assembly facility in Marysville OH. Their production was dictated by the assembly plans at Honda to the point where Honda needed "x" of seat assemblies in Ivory, "y" assemblies in Gray, and "z" assemblies in Black. They would produce them and deliver them and within 1 day, they were installed in a vehicle rolling off of the assembly line.

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331414 01/24/20 09:47 PM
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P10crew Offline OP
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Wow. And they run 24-7?

Re: Auto assembly and mfg. logistics [Re: Papa Bear] #5331417 01/24/20 09:50 PM
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hallstevenson Online Content
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Originally Posted by Papa Bear
Talk about flex manufacturing.
Since you mention "flex manufacturing", another bit of info related to Honda and Ford.... Honda engine plant in Anna OH reportedly can produce one engine design for a half-shift (4 hours) and while the employees, errr, "associates", take their lunch break, convert over to produce a different engine design. The Ford reference goes back to their engine plant in Lima where changing production of engine types (used to) take months. The plant would mostly shut down while equipment was changed over, replaced, etc. The line workers were "laid off" but was effectively a couple month vacation as they were still paid 75+% of their regular wage. This wasn't a yearly occurrence either as they would produce the same engine for years.

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331419 01/24/20 09:54 PM
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P10crew Offline OP
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I suppose there were job shops all around the area of a plant as well?

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331420 01/24/20 09:55 PM
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hallstevenson Online Content
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Originally Posted by P10crew
Wow. And they run 24-7?

Honda or Ford ? Answer to both is "yes". The info on Setex might be slightly inaccurate as what I recall being told was a seat produced in the morning (say during 1st shift, 6am to 2pm), was transported and installed into a vehicle even quicker, like during Honda's afternoon half of 1st shift or maybe during their 2nd shift, i.e. the seats were in a car 8-12 hours after they were made.

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331424 01/24/20 10:02 PM
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hallstevenson Online Content
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Originally Posted by P10crew
I suppose there were job shops all around the area of a plant as well?

In Lima, not so much or not that I'm aware of. Dana has a plant there that makes U-joints. That's all, just u-joints, 3 shifts a day. The M1A1 Abrams tank is made there as well. There's also a large P&G facility that makes Tide (and other) laundry detergent. There were many, many shops that worked with P&G though. The bottling/packaging equipment was built locally by a relatively small (at the time) machine builder shop.

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331430 01/24/20 10:15 PM
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P10crew Offline OP
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Interesting!
I’ve been kinda studying up on the lost foam, precision sand casting process that gm is using for blocks and heads and would really like to see one of those plants.

Re: Auto assembly and mfg. logistics [Re: hallstevenson] #5331503 01/25/20 01:35 AM
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Originally Posted by hallstevenson
Originally Posted by P10crew
I suppose there were job shops all around the area of a plant as well?

In Lima, not so much or not that I'm aware of. Dana has a plant there that makes U-joints. That's all, just u-joints, 3 shifts a day. The M1A1 Abrams tank is made there as well. There's also a large P&G facility that makes Tide (and other) laundry detergent. There were many, many shops that worked with P&G though. The bottling/packaging equipment was built locally by a relatively small (at the time) machine builder shop.

When I worked at a Honda dealer, I saw a weird sticker with the radio codes that said Great Lakes Assemblies, LLC. They are a logistics provider affiliated with Honda that assembled the interiors and wheel/tire sets and shipped them to their Marysville plant pre-sequenced for a particular model.

The Accords came with a kanban sheet that had the codes for all the equipment installed, time of assembly, VIN and the next car for that particular batch.

https://midwestexpinc.com/

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331527 01/25/20 03:06 AM
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I have nearly 30 yrs experience with GM, worked in multiple plants and thru several roles and responsibilities. Currently at the most profitable GM plant - the Arlington Texas plant building all the large SUV's including Escalade..... I can probably answer all your questions lol

Re: Auto assembly and mfg. logistics [Re: P10crew] #5331567 01/25/20 06:22 AM
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I live close to the GM truck plant in Fort Wayne. There’s semis going in and out of that thing 24/7 and rely on the supplier to time things accordingly. Lean manufacturing. They don’t want inventory (tied up money).

IIRC, they are penalized whenever they hold up production by not delivering on time. I get it but at the same time it annoys me. When they were on their strike, they took everybody down with them. I would assume the suppliers are compensated accordingly.


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