As part of an effort to maximize both worker safety and efficiency, Chrysler Group decided to make its Indiana Transmission Plant II as forklift free as possible. To this end, the company contacted Topper Industrial (Sturtevant, WI), a manufacturer of stock and custom carts. The carts are used to deliver parts to the assembly line and to take away finished product.
Chrysler Group Indiana Transmission Plant II (Kokomo, IN) manufactures 5-speed, rear-wheel-drive transmissions for a number of models, including the Chrysler 300, Dodge Magnum, and Jeep® Grand Cherokee. The 600,000 sq ft plant opened in late 2003 and employs around 480 workers.
Individual carts are equipped with 6 high-efficiency casters. The two central casters support the majority of the load, while a pair of casters on each side provides balance. As a result, the carts are easy to maneuver, turning completely around in 8-10 ft of space, depending on the exact model. Thanks to sealed bearings in the casters, an operator can easily push loads of more than 3,000 pounds. Carts can be linked up and towed by electric tuggers.
Initially, Chrysler Group, which had previously used a number of carts at its engine plant in Kenosha, WI, ordered about 125 carts for the Kokomo facility. As designers and engineers refined the organization of the assembly process, that number increased to around 500.
Chrysler Group now uses a number of different stock and custom cart configurations. These include tilting carts that minimize the amount of reaching and bending line workers must do in order to take out the parts being carried in the carts'' bins. Depending on the application, the carts can tilt from 15-60 deg. A simple locking mechanism ensures the load will stay in place. A self-contained hydraulic speed controller regulates the tipping speed when a cart is loaded.
To maximize a worker''s limited space at the assembly station, a "corral cart" was created to transport up to four smaller dollies loaded with trays per cart, yet roll one dolly at a time to the operator. This cart actually consists of a simple framework on casters with spaces that accommodate stacked groups of trays that travel on casters of their own.
When picking up parts for delivery to the assembly area, an employee simply rolls a stack of trays into the corral cart frame and secures it in place with a locking bar. Each corral cart can hold up to four separate stacks of trays and works as well when it is partially full as when every space is occupied. Arriving at a workstation, the employee releases the stack of trays and rolls it to its proper position, then moves on with the rest of the load.
"The corral carts make is possible to put parts right where we need them," says Chrysler Group materials manager Shawn Cross. "They are easy to use, promoting efficiency and safety."