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2019 Ram 1500 pickup production problems costing FCA $300M to fix

Fiat Chrysler is spending more than $300 million to fix production issues with the new 2019 Ram 1500 pickup as the plant where it's built is running below capacity and suppliers reportedly struggle to keep up with building it and the 2018 version simultaneously. The truck's ramp-up is well behind schedule, Automotive News reports. FCA's Sterling Heights Assembly plant in Michigan began building the pickup in mid-January but is running at only 60 percent capacity, CEO Sergio Marchionne said on an earnings call last week. Sources told the publication the plant is still undergoing construction and was building about 1,000 trucks per day toward a run rate of 1,400 per day. It's operating two 10-hour shifts per day, seven days a week, with plans to keep the factory running every weekend and holiday through Labor Day to meet production targets. More than 2,500 of the new pickups were reportedly awaiting unspecified electrical repairs before they could be shipped. FCA could use the boost from the heralded new 2019 Ram 1500, which figures prominently in its aggressive annual financial goals. The company is relying on the previous-generation 2018 Ram 1500, demand for which has been sagging. First-quarter sales of the pickup are down almost 13 percent year over year to 103,964, according to carsalesbase.com figures. Meanwhile, sales of Ford's F-Series pickups over the same period rose 4 percent to 214,191, while Chevrolet Silverado sales have climbed 5 percent to 135,545. Dealers have started receiving deliveries of the 2019 Ram 1500, but only the version fitted with the 5.7-liter V8. The EPA has yet to issue fuel economy ratings for the standard 3.6-liter Pentastar V6 paired with the eTorque 48-volt mild hybrid system, nor the same system mated with the V8. As we noted in our recent First Drive review, upgrading to the (non-hybrid) V8 costs $1,195, which is actually $255 cheaper than before. Related Video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. Image Credit: FCA Plants/Manufacturing RAM Truck sales

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.

Pickup prices rising at 2x industry average

We've said it before, but bears repeating: Pickup trucks are the financial engines of America's automakers. Good thing, then, that the segment is in rude health - in fact, Automotive News is suggesting that pickup truck sales are arguably healthier than they were pre-recession, even though the segment's volume is still significantly down from where it was before the bottom fell out of the US economy. That's because per-unit profits on full-size trucks are skyrocketing, outpacing the industry's average price increases by more than double since 2005. According to data from Edmunds, the average transaction price of a full-size pickup is now $39,915 - a heady increase over the $31,059 average price in 2005 - a gain of over 8 percent after inflation is factored in.
Just how important are trucks to automakers' bottom lines? Automotive News quotes a Morgan Stanley analyst as saying the Ford F-Series is responsible for 90 percent of the company's 2012 profits, and General Motors isn't far behind, with the Chevrolet Silverado and GMC Sierra twins chipping in about two-thirds of the automaker's earnings.
Automotive News points out that Detroit's automakers now have the money to invest in modernizing their full-size truck offerings, in part because they don't have the same overhead and legacy costs that pushed General Motors and Chrysler into bankruptcy. Certainly, the pickup segment has seen a lot of innovations as of late, including turbocharged V6s, coil-spring rear suspensions and active aero. Those improvements in important areas like fuel economy and ride comfort have given existing pickup buyers new reasons to upgrade. In addition, automakers are piling on the tech and luxury goodies, creating more and more high-content, high-profit models like the Ford F-150 King Ranch, Ram 1500 Laramie Longhorn and Chevrolet Silverado High Country (shown).