Global Engine Manufacturing Alliance (GEMA) Receives Top Plant Award from Plant Engineering Magazine

Non-traditional approach to engine manufacturing provides award-winning quality, world-class efficiencies and costs savings

AUBURN HILLS, Mich., Dec. 19 -- Plant Engineering magazine has named the Global Engine Manufacturing Alliance (GEMA) in Dundee, Mich. -- a joint venture between Chrysler LLC, Mitsubishi Motors Corporation and Hyundai Motor Company -- one of three winners of its 2007 Top Plant award. The Top Plant award is presented each year to manufacturing facilities that demonstrate a commitment to excellence in terms of production and product.

The GEMA plant was recognized for its operational excellence through the use of best practices in plant engineering management as well as its use of lean and green operations.

Plant Engineering's editorial staff selected the winners based on the entries they received. The winners are featured in the magazine's annual December Top Plant issue and will receive their awards on April 1, 2008 at the Plant Engineering Manufacturing Summit in Chicago.

GEMA produces a high-tech, fuel efficient family of four-cylinder engines known as World Engines.

"GEMA's success is the result of our people," said Bruce Coventry, GEMA President. "Although we have an impressive state-of-the-art facility with the best machines and conveyors, that's not what makes a great plant. It's the people and the processes that make it great. Education and training are top priorities for our workforce. The commitment of our employees and the dedication of management combined with technical innovations are what allow GEMA to compete with anybody, anywhere."

"From the standpoint of economies of scale, sourcing and investment, we've designed this facility on an entirely different model," said Bruce Baumbach, Plant Manager - GEMA. "From our unique work schedule to our hiring process, which includes either experienced CNC operators, or workers with a minimum two-year technical degree we have people who can identify and fix problems faster than any group of people I've ever seen."

GEMA's non-traditional approach was the result of studying best-in-class systems from several companies in different industries throughout the world. These included inventory management systems, order-to-delivery processes, information management and maintenance processes.

"By combining the best from each, we created an efficient partnership that continues to pay off," Coventry added. "It's really all about execution and teamwork."

The Dundee plant is one of five global manufacturing engine plants for the three automakers. Engine production began in 2005 with Chrysler currently utilizing all engine production at the GEMA plant.

In addition to a state-of-the-art manufacturing facility, GEMA is also a zero-waste-to-landfill plant. In 2006, the GEMA plant removed 100 tons of trash for energy recovery, recycled more than three tons of office paper, 11/2 tons of beverage containers and collected and recycled scrap metal. An onsite waste pre-treatment and tank farm is operated by the City of Dundee.

The 1.16 million square feet facility employs 330 GEMA employees and 265 partner employees who utilize a unique work schedule that puts workers on four 10-hour days with three crews. This allows the plant to operate six days a week with no overtime. Team members rotate through the shifts on a regular basis - working days during one stretch, then moving to the evening shift or the split shift. By utilizing this schedule, workers get an additional 49 days off during the year with no loss in productivity. Additionally, absenteeism is the lowest among the partner companies in the United States. GEMA bargaining unit employees are represented by UAW Local 723, Region 1A.

World Engine

The World Engine is comprised of four different configurations and is available in Chrysler, Dodge and Jeep(R) vehicles. The 1.8-liter, 2.0-liter, 2.4-liter engines are available in the Chrysler Sebring, Jeep Compass, Jeep Patriot, Dodge Avenger, Dodge Caliber and the soon to be released all-new 2009 Dodge Journey. The new 2.4-liter turbo-charged engine is now available in the new Dodge Caliber SRT4.

Dundee, Michigan - GEMA

GEMA and the Chrysler Foundation are active in the Dundee community and have supported several community activities in the area, including the Dundee Firefighters Association, the Mayfly Music Festival and the Dundee Food Service Fund, River Raisin Jazz Festival and the Dundee Veteran's Memorial.

NOTE TO EDITORS: Additional information and news from Chrysler is available at http://www.media.chrysler.com.