BODY IN WHITE

GRG enhanced the Body In White assembly process for lower rails over 15 months, successfully reducing the cycle time from 56 seconds to an impressive 46 seconds, achieving a significant decrease of nearly 18%. This improvement was accomplished by meticulously rebalancing the existing assembly line to eliminate bottlenecks and increase throughput, utilizing advanced spot-welding techniques throughout the operation. The project involved multiple phases, including implementing strategic weld sequence changes, adding 22 new robots, and conducting 64 robot reteach activities to optimize cycle time. GRG also executed 8 fence line changes and managed 28 movements of existing equipment during carefully coordinated production shutdowns. This approach ensured effective retooling while maintaining production quality and efficiency.