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  CASE STUDIES:
DAIMLERCHRYSLER BELVIDERE ASSEMBLY PLANT
LOCATION:     Belvidere, IL
OWNER: DaimlerChrysler
CLIENT: ABB
VALUE: $6,113,281
TRADES: Multi-trade
DATE: January 2007
       
PROJECT DESCRIPTION:
The State Group`s responsibility on this project was to support ABB with their final installation of the Body Shop at Daimler-Chrysler Belvidere Assembly Plant. ABB installed 936 robots, material handling conveyors and body shop operations equipment. State completed ABB`s punch list items from Chrysler and supported ABB with commissioning of the entire Body Shop.
The State Group Inc.`s responsibility on this project was to support ABB with their final installation of the Body Shop at Daimler-Chrysler Belvidere Assembly Plant. ABB installed 936 robots, material handling conveyors and body shop operations equipment. State completed ABB`s punch list items from Chrysler and supported ABB with commissioning of the entire Body Shop.
The scope of work at the ABB Belvidere job consisted of multiple trades. The Ironworkers/Millwrights and Operators were involved in the removal and replacement of robotic units, relocation of robots and modification of end-effectors, which are the end section that handles the parts through the welding and assembly processes. There are three different end effectors located in each robotic cell to produce the three different vehicle models that are produced at this assembly plant (Dodge Caliber launched December 2005, Jeep Compass launched May 2006, and Jeep Patriot scheduled 2006). The robotic unit will switch between the three end effectors depending on which vehicle model is in the production run sequence. In addition to working with the end effectors, State installed updated part locators sent by ABB called `Kits`. State installed and/or re-located brackets that mounted proximity and limit switches. We also had to address any safety issues throughout the Body Shop. The issues consisted of safety fencing, safety pins on parts handling turn tables, parts location pins, conveyor or finger guard. The Ironworkers/ Millwrights on site addressed many areas with overhead conveyors and parts handling conveyors throughout the body shop.

Electricians on this job were responsible for any wiring throughout the Body Shop. This included wiring proximity switches, limit switches, and parts present switches. Electricians completely rewired re-located robotic units and also rewired control cabinets that were wired incorrectly to get the robotic cells up and running. Communications cables were pulled between cabinets and equipment. Grounding and bonding of cabinets, controllers, robots and equipment were installed. Re-wiring of conveyors to make minor modifications to the material handling systems was also completed.

Pipefitters were also used on this project. Their job consisted of installing or modifying any air, water, or hydraulic controls and piping that were used throughout the body shop. Each robotic cell used clamps to lock in the part or multiple parts together for the assembly process. These clamps would need to be replaced or relocated and then be re-piped as needed for commissioning. Multiple locations had stops in the conveyor system that had to be located or relocated.

This work was accomplished over ten months working multiple shifts on weekends and holidays when Chrysler was not in production.

For more information about State Group Inc. and its contracting services, please call 800.558.2034 or email us at info@stategroup.com
 
 
 
           
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