Posted on 09/14/2002 9:31:37 AM PDT by toddst
------------------------------------------------------------------------Posted on Sat, Sep. 14, 2002 Bowling Green plant to build new Cadillacs
BOWLING GREEN, Ky. - Test production of a new line of Cadillac sports cars will create 128 new jobs at the General Motors factory here, although most of them will go to outsiders.
The plant is expected to reach full production by April of the Cadillac XLR, a $70,000, two-seat sports car that goes on sale next year. All but about 20 of the new jobs will go to workers already employed by GM in factories elsewhere.
The Bowling Green plant was specifically chosen for the production because the XLR has the same frame rails as the Corvette, which is made at the plant. Also, its body panels are easily accommodated by Bowling Green's paint shop.
Bowling Green's success with GM's new manufacturing approach and its rising quality ratings were also factors, plant manager Wil Cooksey said.
GM's lean-manufacturing method, dubbed the Global Manufacturing System or GMS, is based on Toyota's approach and tries to get workers to focus on teamwork and quality. It's being implemented at GM plants around the world, and Bowling Green is one of the most successful so far.
Bowling Green used to rank at the bottom of J.D. Power's annual quality surveys, but since 1998, the plant has seen a 49 percent jump in quality ratings. This year, the plant took top honors in its class for the second year in a row and finished second overall in J.D. Power's Initial Quality Survey.
The Cadillac prototypes being built here will never be sold, said production line manager John Spencer. They're merely testing the line and assembly process.
Using GMS principles, Cooksey freed about 18 percent of floor space at the 1 million-square-foot plant, just enough to squeeze in the Cadillac assembly line.
To do that, Cooksey increased the use of just-in-time delivery of parts, changed the layout of the frame shop and installed an electric monorail to move parts across the plant.
He also built a warehouse offsite and moved tire and wheel assembly to a supplier in Nashville, Tenn., who'd been doing the same work for GM's Saturn division.
Many of the concepts are common at high-volume plants such as GM's Pontiac (Mich.) Assembly Center, which makes about 300,000 trucks a year. But they were radical concepts for a plant such as Bowling Green that produced just over 30,000 vehicles last year.
The plant makes about 17 Corvettes an hour and will produce only three XLRs an hour when it's at full production next spring.
The XLR will come with a redesigned Northstar V-8 engine and a new five-speed automatic transmission.
GM said the new engine will be a 4.6-liter, dual-overhead-camshaft V-8 that features polymer-coated pistons, a steel crankshaft and cast-iron manifolds to reduce noise and vibration.
With the new engine, the XLR roadster will accelerate to 60 mph in less than six seconds, complete a quarter-mile in less than 14.7 seconds and have a top speed of 155 mph, the industry's voluntary limit.
I expect this roadster will be more successful than the Allante by a great deal. At the same time I would like to see a warmed up version of the Northstar engine available in the Corvette. The pushrod engine has outlived its usefulness in the Corvette - getting long in the tooth IMO.
Both these cars can benefit from being built under the same roof.
Here's a partial answer.
We doubt if many of the XLR's potential customers will care that it stems from Corvette beginnings. Some may have no interest if a car's body panels are made of composite plastics, aluminum, or Silly Putty. But everything they see, touch, and experience better say "quality and class," or the XLR will go the way of the dodo bird-and the Allanté. We'll know for sure when we see its final pricing and experience that all-important first test. Make no mistake, however: The challenge Cadillac has undertaken is huge.
http://www.motortrend.com/aug02/cadillac/cadillac_f.html
If they do this car right, I'm interested.
The plant makes about 17 Corvettes an hour and will produce only three XLRs an hour when it's at full production next spring.
At three an hour it appears GM is determined to assure quality assembly. In this regard, the Corvette is no slouch at their 17 per hour volume. A good friend has a 2002 ZO-6 and it's very well done.
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