Wholly [in] Toledo!

In July 2003, DaimlerChrysler began converting its Toledo, OH Jeep facility over to accommodate the long wheelbase Jeep Wrangler Unlimited. This wasn't a straightforward task since the Wrangler's assembly facility--the Toledo South Assembly Plant--is the oldest operating automotive assembly facility in the U.S., and encompasses two separate buildings. Stamping, body and paint are located in the Parkway Annex--built in 1904 as a bicycle factory--while trim, chassis and final assembly are located in the nearby Stickney Avenue Plant. Completed bodies are trucked from the Parkway Annex to the Stickney plant in covered trailers.

"The heritage of the Toledo facility and welfare of the workers demanded that we renovate this 'brownfield' site as cost effectively as possible, while adopting the latest technologies and processes available," says Alberto Gonzales, plant manager at the Toledo Assembly Complex. The Toledo facility gained 22 robots brought in from other DCX facilities, which were reprogrammed for their new duties. These included six-axis robots in the paint plant carrying bell atomizers to improve the quality of the Wrangler's paint finish. "The robots were validated using virtual tools, as was the rest of the new tooling," says Byron Green, Chrysler Group vice president--Truck and Activity Vehicle Assembly Operations. "This often meant finding ways to work the new equipment around the low ceilings and concrete posts you find in older plants." The virtual set-up also helped the Toledo plant launch the Wrangler Unlimited during the regularly scheduled changeover without losing a unit of production. "We were shipping units to dealers that hit the quality targets three weeks ahead of schedule," says Gonzales.

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The Jeep Wrangler Unlimited adds 13-in. to the cargo area and two inches of rear seat legroom, increases overall length 15-in. and the wheelbase by 10-in. when compared to a standard Wrangler. Towing capacity is up 1,500 lb to 3,500 lb, but the vehicle maintains the standard Wrangler's 20 breakover angle for off-road driving. "It may have best-in-segment towing, but it had to remain a Jeep," says Green.

The changes made for the Wrangler Unlimited aren't the last for the Toledo facility. Though DCX officials refuse to go into detail, they say a second new facility and new Jeep vehicles are on the horizon. This means at least four Jeep models will be built in Toledo. In addition, studies are looking into the costs and benefits associated with locating suppliers on-site to cut transportation costs and increase quality. "Intelligently renovating existing facilities has allowed us to effectively compete at a lower cost level, while significantly increasing quality," says Green. "Toledo is proof of that."--CAS