New technology increasing ArvinMeritor production

Business Today

DEXTER -- The ArvinMeritor plant, a major employer with about 550 workers, was recently toured by community and state government representatives.

Paul Pratt, quality manager, said the ArvinMeritor Co., which has plants worldwide, is number one in North America and Europe as a cold exhaust system supplier, number one of five suppliers for Daimler/Chrysler, number two of four suppliers for GM and number two of five suppliers for Ford.

"We're the preferred supplier by 55 percent of our customers," he said, adding that ArvinMeritor is consistently improving its quality and beating industry minimum requirements. For example, GM's maximum for defective parts per million is 50; ArvinMeritor's 2001 goal was 39; actual results were 14 defective parts per million.

Increasing output without sacrificing quality is always a goal, said Royce Ellsworth, fabrication supervisor. "We produce 34,000 mufflers a week. Our goal in the next year or two is 55,000."

He said that one of the innovations put into place is a cellular production line that depends on a small group to do what a conventional line would do. "If a man is missing, we don't have to replace him. We just reconfigure the line," he said.

New technology, including robot welders, are also simplifying and standardizing products at the plant, according to unit manager Myron Walker, who has been an employee since the first muffler was made at the plant.

"A lot of good things have been happening here since that first muffler," he said, noting MIG welding formerly done by hand is now automated. "The process has to be robust to be automated and still get a quality product. Better manufacturing techniques also lower errors."

Faster changeovers to meet product specifications also are increasing quantity and quality, especially for after-market service products, said Bill Hatton, assembly unit manager.

"Quick changeovers eliminate a backlog of one type of muffler and helps reduce the chance of an imperfect product. Errors are caught quicker," he said. "Normally, every part we run is set up every day. It keeps down inventory."

Because of its ability to meet customers' needs, ArvinMeritor's Dexter plant is the service center for Chrysler, Ford and GM, according to Tom Frazier, company official. He said there's a lot going on at the Dexter plant.

"Right now we're busy with truck parts, especially GM," he said. "The titanium Corvette muffler, unique to the industry because of its light weight, also is doing well. It's the next step in weight reduction, 40 percent lighter than those made from conventional materials."

Frazier said machinery is being brought in to start production on the new Harley-Davidson motorcycle exhaust pipes, which the plant should start shipping next June.