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Design Systems is proud to have
participated, "from concept to
completion," in DaimlerChrysler's
Toledo North Assembly Plant.
Toledo North is the home of the 2002 Jeep·
Liberty Sport Utility Vehicle, the newest
member of an automotive tradition that began
in 1941. It is also home to the world's most
advanced Flexible Manufacturing Technology.
Design Systems provides engineering and
preject support services to help companies
maximize the preductive capacity of their
people, equipment, automation technology,
and facilities.
We offer complete "walls-in" design, lean
manufacturing plans and implementation,
downtime analysis, bid package engineering,
simulation and emulation studies, and
re-engineering to achieve specific objectives.
Design Systems bui~ its reputation by previding
North America's auto plants and Tier 1 s with
World Class material handling engineering,
and specialized consulting. Today, we are a
comprehensive engineering and management
resource for manufacturers of vehicles and
vehicle systems worldwide, and for some of
the world's most preminent precess plants
and service previders.
DSI OVERALL PROGRAM RESPONSIBILITIES: I. ADVANCE ENGINEERING AND PLANNING • Assist owner in developing program budgets and schedules • Develop preliminary macro scroll to assist in developing the
preliminary process and layouts • Concept development of product carriers using Catia and 3D product information • Perform studies to determine capacity requirements for mechanical utilities • Develop projected contractor trades loading estimates required
throughout the program
II. SYSTEMS ENGINEERING • Develop bid packages and coordinate layout development • Provide finalized scroll to plant IEs to develop preliminary man-assignments • Develop detailed workplace layouts using the man-assignments
developed by the plant • Develop typical electrical control methods and define
equipment interlock requirements • Develop and maintain bulletin/field order change
logs and budget cost roll-ups • Develop 3D Catia conveyor layouts for Paint Shop
and coordinate the entire Paint Shop 3D Catia layout
III. DETAILED ENGINEERING AND FABRICATION
• Ensure that specifications are understood and followed
• Continue to coordinate and develop the details of the schedule
• Update and revise workplace layouts as man-assignments are changed
• Track and coordinate all tooling and facility moves using DSI's Visual Station Database
• Conduct contractor progress and coordination meetings for the Body, Paint and TCF Shops
IV. ENGINEERING ASSISTANCE AND FOLLOW-UP
• Provide daily activity reporting, including weekend work and future task loading
• Monitor and report construction and progress activities • Provide detailed point-to-point validation on all Paint Shop equipment • Participate in equipment and conveyor buy-off activities • Assist owner with the launch implementation plan • Verify accuracy of installation, provide punch lists, and review contractor
"as-built" drawings and manuals
BODY-IN-WHITE Many of the techniques used at
Toledo North were developed and
refined at DaimlerChrysler's Newark,
Delaware, and the Windsor, Ontario
Assembly facilities, where again ,
Design Systems provided facility layout.
material handling design and complete
controls architecture.
Body-in-White Facility Details • 479,260 sq. ft. of manufacturing space • Processed at 53.8 jobs per hour gross capacity • 215 welding, sealing and material handling robots • Automation level is approximately 80%.
CONVEYOR SYSTEMS: • 8,355 linear ft. of inverted power and free track
- 305 inverted power & free carriers
• 2,450 linear ft. of overhead power and free delivery conveyors
- 60 right hand and 60 left hand carriers
New Philosophies Implemented for Body-in-White
• Layout protects for one day model change-over
• Underbody subassembly uses a palletized transfer system.
• Underbody and aperture subassembly uses a cross-platform commonization philosophy.
Body-in-White Engineering
Using precessing infomnation from models and build documents, we produced a plant layout using developed preduction modules and data regarding conveyor routes and lengths, storage requirements, material flow, space allocations, and locations for tooling and equipment.
The Electrical and Controls Engineering Group completed Electrical Power System Load Studies to predict the power needs of various types of equipment. This data is particularly importent for Body Shop welding operations.
Other key operations studies dealt with weld water, compressed air, and process ventilation.
Design Systems provided engineering assistance needed to take the project through installation, launch and start of production, including contractor coordination, manpower loading, documentation and the monitoring of construction progress.
• Coordinate, assist in 20 hour run testing
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PAINT SHOP DaimlerChrysler engineers are employing nDesign for the Environment" initiatives to incorporate
environmental safeguards such as underground spill-containment, more efficient water use, minimal use
of regulated materials, and water-based coatings. One of the important "firsts" in the "Design for the
Environment" initiative is an environmentally-favored paint system that uses lead-free electrocoating which
is also low in both HAPs and vacs.
New Philosophies Implemented for the Paint Shop
• Elimination of the block light booth
• High pressure water cleaning replaced with CO2 cleaning
• Oynamec tool cleaning eliminated
• Phosphate and 8-{;oat standard skid system replaced with inverted power and free conveyor system
Paint Shop Engineering
Design Systems. Inc. developed and maintained the overall Paint Shop layout to keep ~ to an "as designed" status throughout the program. We continually reviewed the layout and implemented cost saving ideas for DaimlerChrysler. We also coordinated and maintained a detailed schedule with over 10,0J) activilies ~ sufficient accuracy to automatically generate monthly invoices based on progress and dollar values tied to the scheduled activities. Throughout the 6-1/2 month equipment installation period we provided detailed drawing and fabrication reviews to ensure quality and specification compliance. Design Systems played a key role in the validation and 20 hour run testing for all of the equipment w~hin the Paint Shop. Our support continued throughout the system try-out period and production pilot runs.
Design Systems Inc. provided "Concept to Commission" Project management and engineering throughout each phase of the 2002 Jeep· Liberty Program.
Paint Shop Facility Details • Processed at 54.0 jobs per hour gross capacity • 727,437 sq. ft. of manufacturing space including
paint mix and sludge system • 52, sealing, painting and handling robots • 74 powder, base coat and clear coat bell applicators • 22 systems in paint circulation including base coat,
clear coat and cleaning systems
CONVEYOR SYSTEMS: • 24,650 linear ft. of inverted power and free track
- 781 inverted power and free earners
• 1440 linear ft. of aiJ'bi.dip conveyors -111 skids
Design Systems provided continuous Catia Model detailed development.
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TRIM CHASSIS FINAL DaimlerChrysler has reinvested mare than $10 billion in recent years in the
communities where the company has its historic roots, transforming sites in
Detroit, Toledo, Indianapolis and ather urban areas where DaimlerChrysler has
operated facilities, same dating to the early 20th century. Design Systems has
been honored to participate in these important renovations.
Trim Chassis Final New Philosophy
• Engine/front suspension is decked to the vehicle from the bottom.
• Each production line is decoupled from the line immediately prior to and following, which allows for repairs to be made in zone.
Trim Chassis Final Engineering
Design Systems developed and maintained the overall plant layout to DaimlerChrysler. Catia and AutoCAD standards. and maintained the interface with all tool ing vendors , conveyor suppliers , and process equipment manufacturers to minimize interferences and assure smooth integration of equipment and facilities.
Extensive benchmarking was performed to ensure a process driven conveyor selection.
We provided engineering services to develop the conveyor system and its support structure, also requirements for equipment installation in Body. Paint and Trim Shops. Timing and transfer studies were performed. carriers were designed and banking/accumulating zones were established for applicable systems. We also provided specialized exper~se in chain pull and drive analysis, clearance layouts and pneumatic systems. Design Systems applied lean and agile techniques that maximized productivity while assuring a high quality build.
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Trim Chassis Final Facility Details • 575,715 sq. ft. of manufacturing space • Processed at 53.0 jobs per hour gross capacity • Automated stripper systems for liP's and seats • Automated front suspension decking and secure • Robotic rolling of door weatherseal • Robotic glass cell
CONVEYOR SYSTEMS: • 10,400 linear ft. of inverted power and free track
- 278 call'iers • 2,930 linear ft. of skillet conveyors
- 137 skillet call'iers with power lifts • 26,633 linear ft. of five overhead power and free systems • 360 linear ft. of flat top conveyors • 2.378 linear ft. of tire and wheel monorail conveyor
- 335 carriers
Trim Chassis Final Engineering
Design Systems assisted project partners in understanding and adhering to specifications and schedules. and provided detailed, ongoing scheduling support.
Design Systems' Electrical and Controls Engineering Group was responsible for the project management of the DaimlerChrysler Quality Alert System. "QAS" is used for tracking vehicles in production, and for communicating this data to other information systems so that build data is available to line workers. The system also includes Automatic Line Stop stations for verification of torque results and zone quality containment.
We performed power and electrical distribution studies for both Body Shop and TCF, and developed detailed workplace layouts for mainline processing using the man-assignments developed by the plant.
Toledo North employs some of the most advanced. proven technologies for assembly and paint processes. On the quarter-mile long Trim Chassis final line. the conveyor system automatically adjusts the vehicle height to the optimum ergonomic position, based on the specific line function.
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DESIGN SYSTEMS, INC.
38799 WEST 12 MILE ROAD
FARMINGTON HILLS, MI 48331-2903
800-660-4DSI • 248-489-4300
FAX: 248-489-4321
DESIGN SYSTEMS CANADA, LTD.
3585 RHODES DRIVE,
UNIT A
WINDSOR, ONTARIO, CANADA N8W 5B3
519-944-8807 • FAX 519-944-8853
DSIDSC.COM
