2006 Chrysler PT Cruiser

The launch of the new Chrysler PT Cruiser Convertible marks another era in the life of the popular, segment-busting PT Cruiser. Production began earlier this month at the Chrysler Group's Toluca (Mexico) Assembly Plant, the same plant that produces the award-winning Chrysler PT Cruiser sedan. (concept carz)
The PT Cruiser era began at Toluca Assembly back in February 2000 with the introduction of the segment-busting vehicle. Most recently, the PT Cruiser tied for first place for the best ownership experience in the Compact Car category of Strategic Vision's 2003 Total Quality Index™.
'We are pleased with the smooth production launch of the Chrysler PT Cruiser Convertible,' said Tom LaSorda, Executive Vice President-Manufacturing, Chrysler Group. 'The employees' dedication to customer satisfaction and the application of proven manufacturing processes and technologies have created a vehicle with the highest levels of quality and head-turning style that is part of the PT Cruiser heritage.'
A cross-functional launch team for the convertible was able to maintain production of the Chrysler PT Cruiser sedan while managing the plant changeover required for the launch. The rolling changeover, which generally involves the addition of new assembly equipment and tooling, quality verification of the equipment and training for new manufacturing processes, was implemented in between the first and second shifts, as well as on weekends. Both the customer and the company benefit from this approach because it enables a faster ramp-up of production and reduces program expenses usually caused by down time.
'The entire team at the plant contributed to the successful operations we've seen at Toluca Assembly,' said Roberto Gutierrez, Vice President-Mexico Manufacturing Operations, Chrysler Group. 'From the ongoing production of PT Cruiser to the rolling changeover, we achieved positive gains in productivity and quality, without missing a day of production.'
Quality Systems
Through the application of team-based operating principles and dedication to continuous improvement, the Toluca Assembly plant has earned a reputation for producing high-quality vehicles with world-class efficiency. Numerous in-plant quality systems, several of which are interconnected, support this effort.
Every area of the plant's operations uses a consistent, quality verification system. This system confirms that the highest level of quality is met at each work zone before a vehicle moves to the next area of assembly. When a potential issue is identified, the plant's Quality Alert System (QAS) allows assemblers to isolate the issue and take immediate action for problem resolution.
Technology also plays a key role in quality verification. In the body shop, a state-of-the-art metrology laboratory checks body panels and assemblies for dimensional accuracy. In the trim, chassis and final assembly area, hand-held testers are used by employees for in-station programming of the electronic systems and verification of their functionality. Optical aiming equipment assures correct headlamp installation and proper headlamp aim for the beams. Each vehicle also is tested with computerized chassis dynamometers that perform final checks before the car exits the assembly line.
Even with the launch of the PT Cruiser Convertible, Toluca Assembly Plant continues to trend favorably in terms of vehicle quality. Warranty costs at the facility were among the lowest of all Chrysler Group manufacturing plants for the 2003 model year and improved more than 20 percent between the 2001 and 2002 model years.
Operational Changes
A number of changes were implemented at Toluca Assembly in preparation for PT Cruiser Convertible production and to add greater plant flexibility. New robotic equipment was installed in the body shop's welding operations for improved precision and efficiency. The trim, chassis and final assembly area was expanded to build both sedans and convertibles.
A new dedicated line was installed for the convertible's underbody process. A combination of robotic and employee-manned work stations weld the PT Cruiser Convertible's underbody, engine compartment and body side systems. This arrangement reduces floor space requirements for a more flexible and efficient plant, which results in the capacity to build additional body lines within the plant at a minimal investment.
Error-prevention devices are incorporated in PT Cruiser Convertible underbody weld fixtures, including clamps to guide panels into place and sensors to ensure all parts are present before welding begins.
Convertible assemblers use a newly installed ergonomic assist arm to position the top module for installation to the vehicle. A fixture then aligns the top to the rear quarter panels, while fasteners lock the top into the proper alignment. Úsing the setting fixture assures a repeatable fit to the vehicle, which helps achieve the optimal fit and finish on the final vehicle.
Most of the PT Cruiser Convertible's interior trim, including the new seats, is installed on the final line. Workers put the seats in the convertible bodies using a combination of new and modified articulated arms that protect the vehicle during installation. The newly modified material delivery system makes the convertible seat installation easier by bringing the seats to the assembler in the installed position.
Hands-on Training from Development to Launch
Training for Toluca Assembly PT Cruiser Convertible operators began early in the development of the vehicle program and was cascaded to the entire work force at the plant. A select group of operators from Toluca Assembly traveled to the Chrysler Group Pilot Plant Facility in Auburn Hills, Mich., where they co-developed and refined the convertible build process. Based on their experience with the PT Cruiser sedan manufacturing process, this group captured and incorporated the sedan best practices into the convertible build before the new vehicle launched. The joint Toluca/Auburn Hills team identified system refinements early to ensure that the product and the process worked together prior to the second phase of pilot vehicle build.
Úsing the first-hand knowledge and experience gained at the Auburn Hills Pilot facility, the original team of Toluca Assembly employees returned to train the rest of the workforce, ensuring a seamless progression to launch.
To further enhance product quality at launch and after, all assemblers were trained and tested for knowledge of both the PT Cruiser Convertible product and related assembly processes that apply to their work station.
More than four years, 1,400 days, 11,000 hours and 610,000 vehicles' worth of PT Cruiser sedan experience go into every single Chrysler PT Cruiser Convertible that rolls off the Toluca Assembly Plant onto highways around the world. During each minute since the successful launch of the PT Cruiser sedan, plant employees have gained experience building the hugely popular vehicle that started a global phenomenon and invented a new segment of personal transportation never known before.

Source - Chrysler