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-   -   Hell, itís easy to build an Overland! (http://www.jeepgarage.org/f73/hell-it-s-easy-to-build-an-overland-12030.html)

vonk 08-17-2010 10:11 PM

Hell, itís easy to build an Overland!
 
Really?

Somewhere I read that the Overland is being built on a new assembly line that can accommodate different models and trims coming down the line individually, rather than in runs of multiple similar cars, and that they are trying to do this with “just in time” parts supply.

Thinking out loud, that would be one hell of a complex system to set up, but once the bugs are out, new orders would not have to wait for enough of them to accumulate for a run. Also, the assembly line would always be busy. On such a line, workers would have to comply with different build sheets from car to car, and be able to install different trims from car to car, all along knowing that if they screw up, Quality Control will know who did it. I presume, QC would be pretty busy (and backed up) at first, and I wonder how they resolve problems. What, and who, can stop the assembly line, and what determines whether a car is rejected, fixed, or “signed off” (problem ignored)?

And then there is the “just in time” supply stream that allows minimum inventories. How minimum? Suppose the NAV system supplier suddenly discovers a problem that holds up delivery of the Media Center. What to do? Just substitute an alternate NAV system or Media center? How easy would that be, with total system integration? So, how much contingency inventory is required before cars are put on the line? Or does a special order just sit there in scheduling until all the right parts are physically in the plant? Just thinking out loud…….

BTW, does anyone here know how long it takes to put an Overland together on the assembly line?

Thoughts?

Thanks J

Marlin 08-17-2010 10:19 PM

Re: Hell, itís easy to build an Overland!
 
Excellent subject, am watching with interest!

Marlon_JB2 08-18-2010 02:12 AM

Re: Hell, itís easy to build an Overland!
 
With fear of releasing too much information, I'll say this

If ALL parts are NOT ready, the vehicle will NOT be built and will be delayed.

Just in time means, in my case, if I need a part at that very... eh I'll say HOUR, it's there, ready for me to grab and install.

Build sheets per car or in this case, Jeep, have existed for years.

Quality control will know "who did it" because this stuff has been tracked by computer for *years*.

No substitutions.

Done with this now. :)

vonk 08-18-2010 09:31 AM

Re: Hell, itís easy to build an Overland!
 
Quote:

Originally Posted by Marlon_JB2 (Post 254358)
Build sheets per car or in this case, Jeep, have existed for years.

While build sheets per car are not new, I trust they will differ much more from car to car on an intermixed line. (ďAny change is a hazardĒ)
.
Quote:

Originally Posted by Marlon_JB2 (Post 254358)
If ALL parts are NOT ready, the vehicle will NOT be built and will be delayed.
Just in time means, in my case, if I need a part at that very... eh I'll say HOUR, it's there, ready for me to grab and install.
No substitutions.

By ďjust in timeĒ I mean supplier delivery directly (almost) to production instead of inventory. How do you guard against parts shortage under those conditions? Multiple sources, inventory cushion, or what? I suppose it depends on the part. I donít think youíd ever want to stop the line for parts shortage. ďJust in timeĒ is probably something to work up to gradually during early production.
.

Technosavant 08-18-2010 10:01 AM

Re: Hell, itís easy to build an Overland!
 
My understanding is that all manufacturers have been working on JIT assembly for years. The Japanese pioneered it- rather than spend money on huge warehouses full of parts that just sat there, the on hand is much lower.

I don't think it is that a part comes off the delivery truck and immediately gets mounted to a vehicle; that's cutting it too close. But instead of having a month or two worth of parts on hand, it may only be a few days' worth. Somebody more familiar with the manufacturing than me will have to chime in regarding the exact figures, but it basically comes down to just not as much slack in the system.

The end result is a disruption at a supplier (labor disputes have caused this) can mean the actual manufacturing plant ends up idled rather quickly.

Marlon_JB2 08-18-2010 11:09 AM

Re: Hell, itís easy to build an Overland!
 
Quote:

Originally Posted by Technosavant (Post 254480)
I don't think it is that a part comes off the delivery truck and immediately gets mounted to a vehicle.

It is, believe me...

I've experienced that very thing myself... several times already.

Jim Hef 08-18-2010 11:11 AM

Re: Hell, itís easy to build an Overland!
 
I watched a TV program on the making of the Z4 BMW. They showed that the seat manufacturer, located a few miles away from the Spartanburg plant, made the seat on order for what was to be produced, shipping the seat the same day, or the day before, to the plant for installation. I don't see why this same process couldn't be implemented by Chrysler also.

Technosavant 08-18-2010 11:20 AM

Re: Hell, itís easy to build an Overland!
 
Quote:

Originally Posted by Marlon_JB2 (Post 254615)
It is, believe me...

I've experienced that very thing myself... several times already.

Ah, you'd know then. I've only read a little bit on it.

J13ntv 08-18-2010 11:32 AM

Re: Hell, itís easy to build an Overland!
 
For anyone thats gone to school or Business, in management class you learn about Just in Time inventory, as well as in Business Strategy. Its actually a very cost effective method and when implemented smoothly, works out to the manufactures benefit greatly. Inventory holding costs, something people don't really think about, depending on the company, can surpass millions of dollars. JIT eliminates that expense while being efficent.

Marlon_JB2 08-18-2010 02:01 PM

Re: Hell, itís easy to build an Overland!
 
BTW: It doesn't matter which trim level you have ordered. Being an Overland doesn't make it special by any means. Well, inside the factory at least. Most of all of the parts are the same anyway. The only difference is trim.

Anywhoozle, a "special" order doesn't matter either, an order is an order. You'll be waiting just as long as the dealership normally would for their own stock.

Steve52 08-18-2010 02:39 PM

Re: Hell, itís easy to build an Overland!
 
Quote:

Originally Posted by Marlon_JB2 (Post 254750)
BTW: It doesn't matter which trim level you have ordered. Being an Overland doesn't make it special by any means. Well, inside the factory at least. Most of all of the parts are the same anyway. The only difference is trim.

Anywhoozle, a "special" order doesn't matter either, an order is an order. You'll be waiting just as long as the dealership normally would for their own stock.

Do you know if there is any advantage to getting your order in with the dealer early, say at the beginning of his allotment cycle (that would be right after he has just ordered all he can for that month), or is it just as quick to wait until he is about at his next allotment cylcle starting point? I ordered mine 5 days after his allotment cycle ended for that month. Would I have been just as well off to have waited until his next allotment cycle was about to end before I ordered it?

vonk 08-18-2010 03:04 PM

Re: Hell, itís easy to build an Overland!
 
Quote:

Originally Posted by Jim Hef (Post 254617)
I watched a TV program on the making of the Z4 BMW. They showed that the seat manufacturer, located a few miles away from the Spartanburg plant, made the seat on order for what was to be produced, shipping the seat the same day, or the day before, to the plant for installation. I don't see why this same process couldn't be implemented by Chrysler also.

On any new production process, JIT will take a while to tighten up. Iím sure the Jeep folks are doing their best on the new Overland production.

JIT requires maximum reliability and responsibility from the supplier, along with draconian penalties for failure. Itís not surprising that the Japanese, coming from a strong culture of obedience, discipline and consequence (Hara-kiri), have pioneered this concept. Americans like to emphasize freedom and individuality, so the degree and speed with which JIT can be implemented may vary from place to place. :)
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