Robots boost for GMM van production

The purpose of this paper is to describe how General Motors (GM) Manufacturing has increased the number of installed robots at its Luton, Bedfordshire, UK van making facility as a means of increasing productivity.

As a result of a study of industrial robots the decision was taken to install Fanuc robots to increase the level of automation. The robots are used mainly for spot welding, though some are used for handling large components.

Over the space of the last four years or so the management of GM Manufacturing has been tackling constraints in the body shop using GMs' throughput improvement processes to achieve greater utilization of its facilities at a time of a gradually reducing workforce.

GM has a process of continuous improvement, which it uses in most of the functions involved in the manufacture of motor vehicles. As part of this process, engineers continually examine ways of removing constraints on the shop floor. Many of these constraints are brought about by the old age of the plant and the confined nature of the equipment. The techniques of continuous improvement are being applied with the aim of bringing up the plant to the point that it is in the best position to win the contract for the next generation of compact light commercial van. If the Luton plant does not win this contract then it would have to examine means of manufacturing other niche vehicles that would allow the plant to continue operations. Alternatively, without further work the prospect facing the plant is closure. The importance of making improvements to ensure the future of the plant is crucial.

Arising out of the increased robot population, the plant at Luton now has the capability for the first time to manufacture over 100,000 vans a year.

For the first time, Fanuc robots have been installed in a plant, which hitherto has used Comau Smart robots. By such a move, two types of robots are being used on the shop floor with the inevitable implications associated with two different control systems.