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Chrysler's internal documents question Ram quality as workers protest

Chrysler is reportedly having a hard time ramping up production of its 2013 Ram 1500. According to The Detroit News, only 16 of the 58 trucks built at the Warren Truck Assembly Plant during the model's first hour passed final inspection. While quality eventually improved over the course of the day, just over half of the units built on Thursday were approved for shipment. Even with workers ordered to stay late to fix their mistakes, some 1,078 units remained outside the facility with defects. The problem, according to workers at the plant, is morale.
According to the report, Chrysler recently changed the shift schedule at the plant and workers are unhappy with the new situation. The new plan has workers split into three shifts, each covering four 10-hour days. With the shifts staggered, some workers now have to work nights and on Saturdays. Some employees are so upset that they've taken to protesting, though the move isn't sanctioned by the United Auto Workers.
Meanwhile, Chrysler admits there were internal issues with the launch, but that the company was able to contain them. A spokesperson has said "plant quality indicators are getting progressively better."

Ram recalling 65k trucks for rear-axle heat treating

A problem with the rear axle has promoted Fiat Chrysler Automobiles to recall a selection of Ram trucks. The campaign affects 2015-16 Ram 1500 series trucks – specifically those manufactured between June 17 and September 28, 2015. All told, that amounts to over 65,760 units across the United States. The issue stems, according to the statements below, from the rear axle shaft. Some of those trucks may have not had those axle shafts properly heat-treated, which could cause them to fracture and separate from the wheel. And that, it should go without saying, could lead to a crash. FCA states that most of the vehicles in question are in dealer hands, but while the manufacturer says it is aware of one accident to have resulted from the issue, no injuries have been reported. The owners of the affected vehicles will be notified to bring their trucks in to their local dealership to have them inspected. If necessary, the dealership with replace the rear axle assembly. This recall follows three prior (but unrelated) ones, also issued for Ram pickups, that between them affected well over a million units. Related Video: RECALL Subject : Incorrectly Heat Treated Rear Axle Shaft Report Receipt Date: OCT 15, 2015 NHTSA Campaign Number: 15V661000 Component(s): POWER TRAIN Potential Number of Units Affected: 65,760 Manufacturer: Chrysler (FCA US LLC) SUMMARY: Chrysler (FCA US LLC) is recalling certain model year 2015-2016 Ram 1500 trucks manufactured June 17, 2015, to September 28, 2015. The affected vehicles may have been built with rear axles that were incorrectly heat treated. CONSEQUENCE: If the rear axle shaft was not properly heated treated, it may fracture and a wheel separation could occur, increasing the risk of a crash. REMEDY: Chrysler will notify owners, and dealers will inspect the vehicles and replace the axle assemblies, as necessary, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is R59. NOTES: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov. ### Statement: Heat-treating October 27, 2015 , Auburn Hills, Mich. - FCA US LLC is voluntarily recalling an estimated 65,760 U.S.-market trucks – most of which are in dealer hands – to inspect and replace, as required, their rear axle shafts or rear axles.

Ram ramping up MI truck production, does deal with Texas Rangers

Thanks to a host of upgrades at the Warren Truck Assembly Plant in Michgan, Ram Trucks is boosting production of the already strong-selling Ram 1500 to build 28,585 more of them a year. That works out roughly to five more per hour, or an additional 100 per day. The major key to the improvements was redesigning 353 assembly workstations to allow employees complete their tasks more efficiently. According to Ram, the expansion was done to meet growing demand for the pickup.
These kinds of comprehensive changes can't happen over night, obviously. From the end of 2013 through the summer shutdown in August, the Warren Truck plant received automation tweaks in the body shop and upgrades to the color booths in the paint shop.
However, the biggest shift was working with "UAW-represented team leaders and operators" to examine every workstation for efficiency improvements. In that analysis, the company identified and altered over 100 problems that could have caused an injury. What really helped to boost the production rate so significantly was moving about 300 parts, or grouping them into kits for better ergonomics, and eliminating walks to grab tools. Once everything was done, about 63 percent of workers at the factory got updated training.