DETROIT -- With thousands of suggestions from line workers, Chrysler Group modified the Warren Truck Assembly Plant in suburban Detroit to build about 100 additional Ram 1500s each production day or 28,500 per year.
That's about a 10 percent increase from 2013 production at the plant, according to the Automotive News Data Center.
The increase required numerous changes, from automation modifications in the body shop to improvements to color booths in the paint shop and assembly line, the company said.
To achieve the increase, Chrysler reviewed every operation at each workstation. About 353 workstations were redesigned. UAW workers drove many of the changes by submitting nearly 7,000 suggestions.
"There was a lot of work done here by the work force. This isn't something that was management driven," said plant manager Curt Towne.
Changes for the additional production began in late 2013 and continued through the plant's summer shutdown in August. The new system was implemented when production resumed.
The plant employs more than 3,800 people, who work four 10-hour days on two shifts six days a week. A 9.4-mile long conveyor system snakes through the assembly area. It takes 25 hours to build each truck.
Once production concludes for the 2014 Ram next month, the plant will have built more than 400,000 units over 15 months. Chrysler would not disclose how many 2015 Rams it plans to build.
Towne said, "We improved productivity by eliminating manufacturing waste."