GM LORDSTOWN Company rewards employees

The assembly plant set records in several areas.
THE VINDICATOR, YOUNGSTOWN
By DON SHILLING
VINDICATOR BUSINESS EDITOR
LORDSTOWN -- All workers at the General Motors Lordstown Assembly Plant were being treated to lunch today after the plant set records in productivity and quality.
The plant last month posted its best month for the number of cars produced, hours worked per car and number of cars coming off the line without defects.
The banner month shows General Motors Corp. that it made the right decision in approving a $550 million upgrade of the assembly and fabrication plants in Lordstown, said John Mohan, shop chairman of United Auto Workers Local 1112.
It's all part of a general trend of improvement the past couple years, he said.
"We keep setting goals that the corporation doesn't think we'll meet, and we are," he continued.
Everyone at the plant had a role in setting the records, so nearly 5,000 boxed lunches are being served during the three shifts to thank workers, said Tom Mock, a plant spokesman.
Improved quality
One record was having 87 percent of Chevrolet Cavaliers and Pontiac Sunfires come off the line without having any problems.
This year's goal was to reach 85 percent; last year's goal was 80 percent. Years ago, this figure was in the 60s, Mohan said.
GM has been stressing improved quality in recent years, and workers on the line are making sure that is happening, he said.
Mock said revisions to the cars for the 2003 model year required some production changes in August, which the plant handled well. Management made a point of soliciting the input of workers and listening to their ideas, he said. "It's a real team effort."
Mohan said a big reason for the improving quality number is GM's change to fixing problems as they are spotted along the assembly line, he said. Cars used to run through the line, and repairs were made after they were assembled.
Now, operators can stop the line if need be to take care of a problem.
"It doesn't compound problems. Instead of having 10 problems later, you have one problem that you can take care of," Mohan said.
Other quality numbers were at record lows in October as well, including the number of cars being held for repairs and the amount of problems found by GM inspectors as cars are shipped throughout the country.
Productivity
Productivity also is getting better. The number of hours worked per car was 19.98 in October, the first time it has been under 20.
The plant averaged 24 hours per car in 2001 and 26 hours per car in 2000, says the annual Harbour Report. The most productive plant in North America in 2001 was GM's Canadian plant, which makes the Chevrolet Impala and Monte Carlo. It averaged less than 17 hours per car.
Mohan said the Lordstown plant has been able to reduce the number of hours needed per car even though the hourly work force has remained steady at about 4,200 the past couple years.
The productivity boost has come from an increase in vehicle production. Last month, the plant produced 36,973 cars, which also was a record. The plant worked overtime two Saturdays because of demand for the cars, but the plant goal was to build about 35,500 even with the overtime.
Mohan said the plant's skilled trades workers have done an outstanding job of maintaining equipment to keep the line running.
shilling@vindy.com