General Motors Wilmington Automotive Facility

Fluor provided construction management, supplemental design, equipment vendor expediting and start-up services for this $300 million project at General Motors assembly plant in Wilmington, Delaware.

This project made the facility one of the most fully automated assembly plants in the world at the time.

Client's Challenge

The retooled Wilmington plant produced the Chevrolet Corsica and Beretta models. The project required total demolition of the existing process and installation of new tooling and conveyors without interference to existing operations.

The project required construction of a new 330,000-square-foot base coat/clear coat modular paint shop, as well as major modifications to the existing plant and production operations. Other facilities included a new computer center, administrative offices, maintenance shop and receiving areas.

Fluor's Solution

Plant modifications included installation of 250 body and paint shop robots and an automated guided vehicle system which transports cars throughout the body shop process. Modifications to the paint system provide new process techniques yielding superior finishes while ensuring full compliance with environmental regulations for waste handling and air quality.

Planning and scheduling of contract packages and coordination between contractors was a critical part of successful project execution. This well-planned approach provided continuity among the different assembly areas, prevented interference with the operating plant, and provided a clear division of responsibilities among the various contractors. The planning and scheduling programs used were site-based and specifically designed to support these activities. The project was carried out with a closed-shop labor approach.

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Conclusion

The program, including total demolition of the existing process and installation of new tooling and conveyors for the 1987 model start-up, was completed in 28 months.