Do they really make Mavericks 24/7? That's 8 Mavericks Every Hour..

[ViperAir]

Most assembly lines run 50 to 60 units per hour. Hermosillo builds Bronco Sport as well.

Assume they build 25 to 30 Mavericks/hr, assuming a 50/50 split between Mav and BS.

While the plant "operates" 24/7, it is most likely on a "3 crew" schedule and doesn't actually run 24 hours, 7 days of non-stop production.

This is the 3 crew schedule for US based plants - assume it's the same for Mexico.
A crew works Monday-Thursday day shift 10 hours (can be scheduled up to 11.7)
B crew works Tuesday-Friday night shift 10 hours (can be scheduled up to 11.7)
C crew works Fri/Sat day shift, Sun/Mon night shift, 10 hours (can be scheduled up to 11.7)
Overtime shifts can be ran on Sat nights and Sun mornings.

The plant doesn't run non-stop 24/7. There needs to be downtime for maintenance and repairs to production line.

Edit - found an article (https://www.freep.com/story/money/c...or-chip-shortage-plant-production/7811355002/) from last year claiming Hermosillo runs 2 shifts. If they have parts I'd guess they run 10 hours/shift, 5 days per week. Approximately 1200 vehicles per day, split between Mav and BS.

Thanks, that is really good info...

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[aspect]

I am worry about the guy forgetting to grease the robots...lol

Worry not! They only need to be greased every 11000hrs and there is a reminder posted in the preventive maintenance system about it when it's coming up. And the health monitoring software will notice any changes that may have come about due to insufficient greasing.

Industrial robots are pretty great! Just greasing and battery replacements for the first 44,000hrs of runtime.

 

[mco30mco]

I was checking the operating hours for Hermosillo Plant, and it operates 24/7. Anyone know if that is true??

Is that standard practice of the Auto Industry to operate plants around the clock??

24/7 is 168 hours, with 6000 Mavericks a month, that's about 8 Mavericks every hour...

Capacity of the plant was improved to 300,000 units per year. The plant was top rated in the category of "Compact Premium Conventional" for 2007 in terms of productivity, taking an average of 20.78 hours to assemble a vehicle, per Wiki......

So about 1/4 of Hermosillo is devoted to Mavericks...

The jobs per hour is probably between 60 and 70 with a goal of 72ish. In a parts plant you are lookin at 160 ish parts per hour. It’s fast work in a factory and it’s not easy.

 

[aspect]

The jobs per hour is probably between 60 and 70 with a goal of 72ish. In a parts plant you are lookin at 160 ish parts per hour. It’s fast work in a factory and it’s not easy.

Yep, this guy factories

 

[Skeeter163]

The F-150 plant at Norfolk Va. ran two shifts and a third for maint.
7 days a week

 

[ViperAir]

Thanks for the insight with the factory work...

 

[Dimes]

Wondering if the quality is better during the day than after midnight when they are barely awake...lol

When I worked at a company making transformer tanks quality and productivity was always much better over night. The day shift were always old timers that didn't care anymore and did the bare minimum or knew that any mistakes they made would be corrected by night shift so management never saw it.

 

[Fancy Farm]

Wondering if the quality is better during the day than after midnight when they are barely awake...lol

People that work midnights are not barely awake. Where did you get that idea?

 

[garryjohnson]

Wondering if the quality is better during the day than after midnight when they are barely awake...lol

I have worked nights (security) for the last six years and I sleep during the day, so I am wide awake at work. Most of the time, I get six to eight hours of sleep. The difficult part is getting my friends to not call me during the day while I'm sleeping. I have one friend that could not get it through his head, so I called him twice at 0200 (2AM) and he finally got the message.

 

[hellokitty1984]

As someone who works one month of night, 6am-6pm, and one month of days, 6am-6pm, I can confirm that if done correctly, you're not sleepy during the night shift. In fact, quite the opposite. The only difference between day and night is needing more supplemented vitamin D. I am sure they can efficiently work if provided parts needed to get the job done.

 

[Bigfoot86]

I am worry about the guy forgetting to grease the robots...lol

So, I can weigh in on this. I work at Dearborn Truck and I'm one of the guys who greases robots, along with various other machinery repair and maintenance.

Most high production auto assembly plants are run around the clock with very short (1-2 hour) breaks in production on normal days, and a 24-36 hour break in production weekly. A couple major reasons plants run around the clock is, as previously mentioned, Just-In-Time production supply chain models can't just stop often because it causes backups and bottlenecks in production. Another reason is that it's often easier to keep production workers on the line, making fewer products, than it is to start laying people off or having part time workers. Lastly, if you shut down a lot of machinery, it starts to degrade relatively faster than if it's kept running. There's a lot of machinery and production equipment that will set in it's ways if kept idle; i.e. mastic pumps, auto sealant/paint application equipment ey cetera.

Hope this shed some light from an inside perspective.

 

[Watchman]

Hermosillo can stamp 35 Mavericks OR 37 Bronco Sports an hour - not both at the same time. That means the line, at full speed, only assembling Broncos, can build 37 units per hour max. At present, they are running 2 shifts, five days a week. Although the website says it's open 24/7, that doesn't mean they are assembling. My source says the line is running at about 32 units an hour. The previous post that states it takes about 20.5 hours to build one unit is correct, but that isn't one day of assembly. It takes more than one day to build your Maverick.

With the supply chain issues and today's economy, overtime pay would not be sensible. Even though the plant is in Mexico, the workers are union organized so eight hour shifts a day would make sense. We know the demand is there so when the supply issues ease, a third shift would bring production to capacity without going to the expense of overtime pay.

**Approximate production week:
32 units x 8 hour = 256 x 2 shifts =512 per day
512 units x 5 days = 2,560 units a week.
(**Mavericks, Bronco Sports, or combined)

 

[Tiger Dude]

Wondering if the quality is better during the day than after midnight when they are barely awake...lol

My experience in plants is they almost always run better overnight when managers are home.

 

[Benilla]

You can only build as many trucks as you have materials for so no, its not 8/hour because they don't have all the parts readily available due to supply chain issues. It'd be more accurate to say they COULD max out out and make 8/hour

 

[stlowe36]

Wondering if the quality is better during the day than after midnight when they are barely awake...lol

Just an opinion, mostly better at night. Less engineering interruptions. We engineers, always want to run projects during the day to avoid OT, since we don't get paid for OT.

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