Chrysler PT Cruiser Production Reaches Full Speed to Meet Worldwide Demand
30 June 2000
Chrysler PT Cruiser Production Reaches Full Speed Early And Gains More Units to Meet Worldwide DemandToluca Assembly Plant achieves maximum daily rate of 40 vehicle per hour ahead of schedule, without loss of vehicles, resulting in 4,000 gained units; Quality indicators are a new launch benchmark for the Chrysler group; European PT Cruiser production plans underway in Graz, Austria AUBURN HILLS, Mich. - Customers around the world waiting for their Chrysler PT Cruiser will be glad to know production is running at full speed, ahead of schedule at top quality levels. In response to overwhelming worldwide demand for DaimlerChrysler Corporation's hot-selling Chrysler PT Cruiser, the company's Toluca Assembly Complex achieved its maximum level of PT Cruiser production today, two weeks ahead of schedule. By improving efficiency, working with suppliers and working some overtime, the plant gained approximately 4,000 additional units for the year. Likewise, the Eurostar Assembly Plant in Graz, Austria is beginning to modify its tooling and finalizing supply chain logistics in preparation for European Chrysler PT Cruiser production, which will begin in early summer 2001. There are currently 14 Eurostar engineers in Toluca benchmarking best practices as they prepare to launch the vehicle in Graz. "From Times Square and Sunset Boulevard to the Champs D'Elysee and Potsdamer Platz, PT mania is sweeping the globe," said Jim Holden, DaimlerChrysler Corporation President and CEO. "The phenomenal interest for this vehicle helps underscore the potential growth for the Chrysler brand worldwide. With current vehicle production reaching its top level ahead of schedule, we are doing everything we can to meet the overwhelming customer demand worldwide. As production begins in Graz next year, it will free up more North America allocation, where demand is the strongest. Quality indicators and initial warranty results for the Chrysler PT Cruiser have set a new benchmark for the company. This is the best Chrysler launch we've ever had." Since its debut in January 1999 and its recent arrival in driveways around the world, customers have been lining up to place their order. The PT Cruiser went on sale in April in North America, and May in Europe and Japan. The hard work of the launch team and the flexibility of the Toluca facility, in Toluca, Mexico, enabled the facility to reach the maximum rate of 40 vehicles per hour, two weeks ahead of schedule. The Toluca facility will be able to produce 180,000 vehicles annually, with another 50,000 coming from Graz, for a total of 230,000 vehicles annually. Approximately 3,400 team members operate on two, nine-hour shifts at the Toluca complex. The plant currently produces both right and left-hand drive 2.0-liter and 2.4-liter versions for the world market. As Chrysler PT Cruiser production has ramped up, production of the 2000 Chrysler Sebring Convertible decreased there as it shifts to the Sterling Heights Assembly Plant in Detroit. Sterling Heights is currently ramping up production of the all new 2001 Chrysler Sebring Convertible, Chrysler Sebring sedan and Dodge Stratus sedan. The flexibility of the Toluca facility enabled the company to launch the PT Cruiser, while continuing to build Chrysler Sebring Convertible (as well as Mexican versions of the Chrysler Cirrus and Dodge Stratus) -- all without losing any production volume. "Because of the increasing flexibility of our manufacturing facilities, we're able to build pre-production vehicles in the plants, on our assembly lines much earlier," said Gary Henson, DaimlerChrysler's Executive Vice President - Manufacturing. "The benefits are tremendous: Flexibility enables us to produce a higher-quality product much sooner, for lower cost, less downtime and with minimal production loss. This represents huge productivity and efficiency improvements. In the case of Toluca, we haven't lost any production, and we've stayed focused on quality throughout the entire process. It's a success story for the PT Cruiser launch team in Toluca and in Auburn Hills." PT CRUISER QUALITY SETS A NEW BENCHMARK Internal quality measures for the PT Cruiser as well as the first two month's warranty claims set a new benchmark in quality for a Chrysler production launch of an all new vehicle. "The PT Cruiser launch has been our best ever, in terms of quality," said Henson. "The goal of continuous improvement is to get better, and we continue to raise the bar with every launch." Toluca was one of many plants benchmarked by the worldwide DaimlerChrysler manufacturing group in developing best practices for the companies Operating Principles, the comprehensive system it uses to produce vehicles. To ensure quality, the Toluca plant verifies parts, processes and fit and finish every step of the way -- from stamping and body, to paint and final assembly. Some of quality assurance processes include: * Measuring dimensional accuracy of eight full bodies per day by determining millimeter variances in the x, y and z axis of 5493 points on the body; * Visual Management through quality alert systems, which are designed to bring abnormal conditions to light immediately. * The system provides visual and audible signals for each station for tooling, production, maintenance and material flow; * The addition of 55 robots in the dimensional and integrity welding areas, including two framing stations; * Daily weld and sealing audits, performed by ultrasonic weld detection; * Daily body, paint and assembly audits for internal and exterior evaluation; * 100 % Electrical and mechanical systems audits; * 100 % water tests; * Daily customer satisfaction audit (CSA); and * 100 % Road test evaluation on the Toluca proving grounds