MANUFACTURING The new Range Rover manufacturing facilities at the Solihull site represent GBP 70 million of the GBP 300 million investment in this new vehicle. The main areas of investment on site are:- Body-in-White Paint Trim & Final Assembly Power Train BODY IN WHITE The vehicle first begins to take shape in the all new Body in White (BIW) facility, a 6,600 square metre dedicated area within the East Works plant. Here the sub assemblies that make up the monocoque and the body panels come together on a new framing line before progressing via a final body line to the paint shop. The new Range Rover BIW plant is more compact than the existing lines as the body parts arrive at the plant as larger sub assemblies and the framing line is completely automated. The new Range Rover BIW facility employs a total 130 employees and has a current base capacity of 16 body shells per hour and represents a GBP 15 million investment. The 260 body panels that make up the body shell are supplied by Rover Body and Pressings at the Swindon plant. They are delivered as individual panels, with the exception of the bonnet which arrives complete, and some other panels are delivered complete with weld nuts fitted. The body framing facility consists of 14 sub assembly zones where panels are jigged and welded manually to create the main constituents of the body frame:- Front End Main Floor Rear Floor Body Sides Roof This body framing sub assembly zone uses 120 jigs and over 140 welding guns. The sub assemblies then move on to the main framing line where they pass through nine stations. The body is automatically jigged using pins and clamps and 60 welds are applied. The cycle time for this operation is 3.3 minutes per body. The body then progresses to the main robot weld station where two robots apply 264 welds. These two robots effectively do the job of six by automatically changing their welding heads three times during the process cycle. The body frame finally passes to the manual finish weld stage where those welds that are not accessible by robot are completed. The doors and tailgate frames are assembled using 31 jigs and 23 welding guns prior to passing through six power clinches when the aluminium skin is joined to the assembly. The completed body frame assemblies then pass along the final line where doors, bonnets, wings, and tailgates are fitted and set to the correct clearances. The final operation in BIW is a cosmetic inspection under high intensity lighting before the completed body shell passes via a lift into the paint shop. PAINT Over GBP 3 million has been invested in upgrading the existing Paint Shop. The facility is one of the largest in the UK and is situated on three floors of a self contained unit. Body shells are stored on the ground floor where they are sequenced for processing. The main paint process takes place on the first floor and the stoving ovens are on the top floor. All ancillary equipment and plant not directly involved in the process is kept isolated in the interests of fume, contamination and dust control. The result is the best possible working environment for operators to aid them in their task of striving to obtain the optimum paint finish. The company took advantage of holiday shut down periods to install a number of new facilities including:- Overhead conveyors Colour application machine Underseal booth Surface distribution system Anti-chip application Other facilities were uprated or relocated to make better use of the existing facility such as the electrostatic application and the sealer line. The Buy Off line has been extended and the lighting improved to enhance quality control. The first stage of progress through the paint process is the corrosion protection provided by a zinc phosphate conversion, applied in an eight stage spray process. The combination of steel and aluminium used in the production of all Land Rover products demands a high degree of specialised expertise in chemical processes gained through over a quarter of a century. Corrosion protection is further enhanced by PVC seam sealing and underbody coating being carried out prior to primer surfacer paint application by high voltage electrostatic equipment. The final colour coat is also applied by high voltage electrostatic equipment. The various paint finishes require special formulation to cope with the demand of sometimes vigorous off road use. The new Range Rover gets additional stone chip treatment to vulnerable panels. TRIM AND FINAL ASSEMBLY Painted body shells are delivered to the sequencing area at the beginning of the new Trim and Final assembly line in North Works. Body shells are loaded onto the line in strict order to ensure they meet with the correct trim and engine. Before the vehicles are entered onto the production line they are fitted with protective panels to safeguard against accidental damage to the paint finish during the assembly process. After the body shell is entered onto the line, the doors are removed. They travel round their own assembly line where glass, winder motors, speakers and trim are fitted. They then rejoin the vehicle towards the end of the assembly line sequence. The trim and final assembly is divided into two main production lines, a chassis build area and line-side sub assembly build and test areas. The first main production line is the Body Line and after the doors have been removed the main tasks of this zone include sun roof fitment, under body assembly work, glazing and installation of the fascia and other electrical wiring. The engine, transmission, axles, suspension and fuel tank are put together in the chassis build area, the end of which joins the other main production line, the Mount Line. This is where body, chassis, engine and transmission come together for the first time and is the beginning of the final assembly process. On this final line the seating is fitted, the vehicle has coolant and brake fluids added and the bumpers, doors and wheels are assembled onto the vehicle. At the end of this line, fuel is put into the vehicle and it is driven off the line to go through a series of tests and calibrations which include a rolling road, water and electrical testing and calibration of electronic air suspension and steering. The Trim and Final Assembly line is a completely re-facilitated 35,000 square metre assembly hall, developed at a cost of over GBP 13 million. Although the production line uses only one robot station - the glazing cell - this new line features power assisted machinery to make light work of lifting and locating heavy items such as doors, wheels, sun roofs, seating and fascias. The facility has also been designed to eliminate the need for excessive stretching and bending to allow operators to concentrate more on the quality of the tasks which they perform. POWER TRAIN One of the only facilities that Land Rover does not have on site is a foundry. All other work to produce the V8 engines, R380 gearboxes, differentials and axles is carried out at Solihull. All machining, heat treatment, assembly and testing takes place on site. The Power Train business unit employs 4,000 people at Solihull and, in order to keep Land Rover Vehicles production supplied, works both day and night shifts. Major enhancements to the engine build plant in North Works include new crank and con rod machine lines and a number of multi-spindle nut runner and torque units are used on cylinder head, con rod joint, main bearing caps and sump pan assembly. The new 4.0 litre and 4.6 litre V8 engines are built on Automatic Guided Vehicles that move from station to station following magnetic coils embedded in the floor of the building. On completion all units are sent for testing before being mated with a gearbox. The R380 gearbox now fitted to all manual vehicles is produced at a new facility employing over 100 people in South Works. The gearboxes are built on a production line and every unit is tested before being mated with the transfer box and then the engine before being shipped to the final assembly lines. Development and installation of this new facility which started production in the Spring of 1994 totalled over GBP 8 million. Front and rear differentials and axles are assembled next to the gearbox and transfer box lines in South Works. PEOPLE Land Rover's greatest asset is its employees. The new vehicle and production facility has provided the opportunity to develop the principles of openness, empowerment, improvement and personal development that were laid down in the Rover Tomorrow package. The first people to work in the new facility were the team leaders who were trained to carry out all the assembly operations in either final assembly or Body in White. By obtaining a wide degree of knowledge and flexibility they became the natural leaders of the cells when people were recruited for the main build. The team leaders also developed the framework of the new culture and working practices, known as CONQUER that are accepted by all who work on the new Range Rover. As the Trim and Final assembly and Body in White areas were both to start with a completely new facility the opportunity was taken to enlist the involvement of everyone operating in the new plant. Every detail, from the layout of the machinery to the colour of the walls, was agreed by all in the area. The most significant development, however, was the drawing up of a series of principles of conduct for all members of the team - CONQUER- Commitment Openminded teamwork No second best Quality image Utmost honesty Effective communication Respect Recognising that flexibility is an important factor in the new culture, even the above principles are constantly open to question and improvement. The results of these practices are obvious to all who visit the area. For example, in the interests of safety and quality, jewellery such as rings and wrist watches have to be covered at all times. Meal breaks are taken in the designated rest areas which are also used by office staff and management. All employees are responsible for maintaining these areas to a high standard of hygiene. The total range of skills necessary to support the tasks of a cell are carried out within that cell. For example, pallets are now on wheels so that they can be moved by hand, but some operators will be trained to use the new electric tugs, eliminating the need to wait for a fork lift truck when more materials are needed track side. Employees have also committed themselves to personal principles such as helping colleagues, honest communication, recognition, and allowing time for humour and enjoyment. -- _ __ Apricot Computer Limited Tel: (+44) 21 717 7171 ' ) ) / 3500 Parkside Fax: (+44) 21 717 0123 /--' o _. /_ Birmingham Business Park / \_<_(__/ <_ BIRMINGHAM B37 7YS Email: richardj@apricot.co.uk Richard Jones United Kingdom ..!uknet!apricot!richardj