Process Development

Case Studies
Process Development


Automotive Assembly Plant Process Development for a New Product


General Motors Corporation


  • Develop new assembly processes for Body and General Assembly departments.
  • Compare new processes to existing plant operations to define potential impact on facility.
  • Determine new requirements for assembly process stations and layout impact.


Plan for a significantly different new product and process to be built in an existing assembly plant.

“Bottom Line” Results

  • Developed new product processes and sequence requirements.
  • Developed new product workstation, line length and subassembly area requirements.
  • Determined layout changes needed to optimize material and process flows.
  • Quantified labor requirements for the new process.
  • Established budgetary cost estimates to incorporate the new process.