Case Study: Daimler Chrysler

Business Challange

  • DCX was challenged to integrate an elevated tire and wheel delivery system over a live assembly line without disturbing production.
  • The DCX Saltillo plant of Mexico produces the Dodge Ram Super Cab Pick-Up Truck. The tire and wheel system delivers truck tires mounted on rims to each side of the assembly line “just in time” and “in sequence” for each truck on the assembly line. A single tire line will divert tires to the LH and RH side of the assembly line.
  • The current obsolete conveyor was typical 2.5” heavy duty Chain Driven Line Roller (CDLR) with UHMW friction roll sleeves. It was a challenge for BMH to convince Durr to consider the use of Hytrol ABEZ electronic zero pressure accumulation conveyor. DCX had a very aggressive project schedule to have the conveyor on site for installation within five weeks of the order.

The Solution

  • DCX contracted BMH to equip the Chrysler plant with a two phase installation plan to install the new Hytrol ABEZ conveyor around the current system with absolutely no interruption to Chrysler’s production. Durr provided controls, labor and the overhead steel structure. The EZ Logic was a great success and saved Durr capital expenditure with controls equipment and installation.
  • The Phase I cut-in allowed DCX to use the new ABEZ conveyor, which was suspended on a new cat walk steel structure over the assembly line. The conveyor fed an existing pair of 17’ high gravity wheel silos, one for each side of the line.
  • The Phase II conveyor was installed and extended additional ABEZ conveyor 430’ upstream and parallel with the assembly line, 12 feet above the plant floor.
  • BMH provided two new gravity tire silos with escapements and chain transfers.
  • The final “cut in” disconnected the existing pair of silos and allowed all the plant tires to flow down the new BMH conveyor feeding the assembly line where workers stacked the wheels and put them on the trucks. There are between 5 to 7 tires for each truck including a spare and dual rear wheel as required.

The Results

  • After several weeks of running production through the new conveyor the Hytrol ABEZ conveyor performed with great success. DCX realized that the typical automotive specification to provided very heavy and costly CDLR with larger drives and increased maintenance was not required. Chrysler has used the Saltillo plant as a benchmark for additional projects that are currently planned.
  • The Saltillo DCX plant approved and is utilizing an expansion of an additional tire and wheel marriage system and was awarded to BMH Novi. Durr of Mexico was the prime for this project who requested the RFQ from BMH.