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The HARBOUR Report™ - Automotive News

1 The HARBOUR Report 2007 North America Press ReleaseMANUFACTURINGCOMPANY BY COMPANYPLANT BY PLANT 2007 HARBOUR Consulting. All rights News1 Industry Overview2 Performance Data3 Conclusions42 2007 HARBOUR Consulting. All rights Headlines Toyota leads the six largest competitors in total manufacturing productivity (assembly, stamping, engine and transmission), using labor hours per vehicle. GM captures 3 of 4 Best Plant awards. Honda leads the six largest companies in vehicle assembly productivity with hours per vehicle. The gap among the six major North America automakers continues to narrow. The correlation between quality and productivity continues to strengthen.

1 The HARBOUR Report™ 2007 North America Press Release MANUFACTURING COMPANY BY COMPANY PLANT BY PLANT ©2007 …

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Transcription of The HARBOUR Report™ - Automotive News

1 1 The HARBOUR Report 2007 North America Press ReleaseMANUFACTURINGCOMPANY BY COMPANYPLANT BY PLANT 2007 HARBOUR Consulting. All rights News1 Industry Overview2 Performance Data3 Conclusions42 2007 HARBOUR Consulting. All rights Headlines Toyota leads the six largest competitors in total manufacturing productivity (assembly, stamping, engine and transmission), using labor hours per vehicle. GM captures 3 of 4 Best Plant awards. Honda leads the six largest companies in vehicle assembly productivity with hours per vehicle. The gap among the six major North America automakers continues to narrow. The correlation between quality and productivity continues to strengthen.

2 Improved labor productivity allows money to be redirected to make future vehicles more appealing. Flexibility through more competitive agreements is beginning to pay off, but more must be done. GM and Ford buyouts partially offset volume losses, and will have a bigger impact in 2007. Fewer plants are producing more vehicles and a wider variety of models supported by flexibility and productivity gains throughout the industry. 2007 HARBOUR Consulting. All rights American Market ShareCar / Truck VolumeCar / Truck Volume1989 & 2006 1989 & 2006 Truck VolumeCar Volume1989200619892006198920061989200619 8920061989200651%51%71%29%39%61%67%33%33 %67%59%41%0%100%41%59%24%76%44%56%28%72% 42%58%14%15%24%17%34%24%5%9%5%6%6%15% Market Share Percentages3 2007 HARBOUR Consulting.

3 All rights Utilization Range100%100%88%77%93%93%103%77% 2007 HARBOUR Consulting. All rights American Pre-Tax Profit Per Vehicle($1,072)$226($5,234)($50)($1,436) $701$1,368$1,581$1,575$2,069$1,266$1,214 20022003200420052006 Percent Changefrom 2005-30%13%-20%-581%43%-787% DCX / Ford / GM- data based on calendar year Honda / Nissan / Toyota -data based on fiscal year Currency Conversions: 108 Yen / Euro4 Vehicle AssemblyMANUFACTURING COMPANY BY COMPANY PLANT BY PLANTMANUFACTURING COMPANY BY COMPANY PLANT BY PLANT 2007 HARBOUR Consulting. All rights Hours Per Vehicle (HPV) MeasureAll units producedHours worked by all plant personnel Salary Direct Hourly Indirect Hourly5 2007 HARBOUR Consulting.

4 All rights of Vehicle Assembly - HPVGM excludes Medium Duty plants. Honda and Toyota data include partial reporting of North American Per Vehicle: Body, Paint, Trim, Chassis, and Final AssembHours Per Vehicle: Body, Paint, Trim, Chassis, and Final AssemblylyPercentChangefrom ** Nissan data estimated by HARBOUR with publicly available data 2007 HARBOUR Consulting. All rights Company Assembly Labor ProductivityHours Per Vehicle (HPV)Hours Per Vehicle (HPV)HPV% = Percent change 2005 - 2006 Industry Average includes all companies. GM excludes Medium AverageCompanies not ranked due to partial reporting of ** Nissan data estimated by HARBOUR from publicly available data6 2007 HARBOUR Consulting.

5 All rights Ten Vehicle Assembly Plants*Hours Per Vehicle*Hours Per #2 LordstownChicagoNUMMI CarAlliston#1 and ELPF airfaxCAMIK ansas City #1 Oshawa #1 Oshawa #2 Allure, Grand Prix, LaCrosseEquinox, Torrent, XL-7 Aura, MalibuCorolla, VibeCobalt, G5, PursuitImpala, Monte CarloEscape, Mariner, TributeFive Hundred, Freestyle, MontegoCivic, CSX, CR-V, Element* Ford Atlanta ( ) not included due to plant idling in October 2006 Camry, Hybrid Camry, Solara 2007 HARBOUR Consulting. All rights Segment Ranking Top EastSt. Louis #2 AtlantaNUMMI CarELP/Alliston #1 Spring HillMidsize Non-Premium ConventionalMidsize Non-Premium VanIONC ivicCorolla, VibeTaurusAllure, Grand Prix, LaCrosseAura, MalibuCaravan, Cargo Van Town & CountryCaravan, Town & CountrySiennaCompact Non-Premium Conventional7 2007 HARBOUR Consulting.

6 All rights Segment Ranking Top 3 Compact Non-Premium win CitiesShreveportNUMMI TruckWindsorRamos ArizpeChicagoELPCAMICAMIM idsize Non-Premium CUVM idsize Non-Premium PickupTorrentEquinox, XL-7CR-VRendezvousFreestylePacificaTacom aCanyon, Colorado, I-SeriesB-Series, Ranger 2007 HARBOUR Consulting. All rights Segment Ranking Top City #2 Fort WayneMoraineToledo NorthJefferson Non-Premium PickupLarge Non-Premium UtilityNitroGrand CherokeeAscender, Envoy, RainierSierra, SilveradoF-SeriesF-SeriesDurangoSuburban , Tahoe, Yukon, Yukon XLSuburban, Tahoe, Yukon, Yukon XLMidsize Non-Premium Utility8 StampingMANUFACTURING COMPANY BY COMPANY PLANT BY PLANTMANUFACTURING COMPANY BY COMPANY PLANT BY PLANT 2007 HARBOUR Consulting.

7 All rights Index MethodologyParts Per Parts Per HourHourParts Per Parts Per Labor HourLabor HourAverage Die Average Die Changeover Changeover TimeTimeParts Per Parts Per LineLineOperating Operating Hours Per Hours Per Die ChangeDie Change9 2007 HARBOUR Consulting. All rights LibertyPrinceton WestNUMMIT olucaSilaoDearbornBelvidereStamping - Top Ten Plants 2007 HARBOUR Consulting. All rights Measures By Company684638687624624709789631803764200 22003200420052006 Parts Per Hour (PPH)Parts Per Hour (PPH)1%1%7%-3%-16%Percent Changefrom 200510 EngineMANUFACTURING COMPANY BY COMPANY PLANT BY PLANT 2007 HARBOUR Consulting.

8 All rights Per EngineHours Per 200511 2007 HARBOUR Consulting. All rights Ten Engine Plants - Hours per HillWest VirginiaDundee - GEMAG eorgetownFlint SouthLimaFlint NorthTonawandaAnnaMack Avenue L4 L850 Turbo; , L4 I4, , , L4, L4 Hybrid, I6 L4 L850; , I4; , I5; , L4 CNG; L4; , , L4; , , , V6 2007 HARBOUR Consulting. All rights Segment Comparisons - Top 36 Cyl HillGeorgetown West VirginiaMack Ave. IIWest VirginiaFlint SouthKenoshaFlint oMack Ave. tha rine sSaltilloRomulus*Gasoline engines only8 Cyl OHC6 Cyl OHC4 Cyl OHC8 Cyl OHV12 TransmissionMANUFACTURING COMPANY BY COMPANY PLANT BY PLANTMANUFACTURING COMPANY BY COMPANY PLANT BY PLANT 2007 HARBOUR Consulting.

9 All rights 5 Transmission Plants - #2 Ramos ArizpeKokomoLivoniaTop 5 PlantsTop 5 Plants4L60E, 4L65E, 4L70E RWD 4-speedW5A580 RWD 5-speed4L60E, 4L65E RWD 4-speed42 RLE RWD 4-speed, A604 FWD 4-speed, RWD Heavy Duty4R75W RWD 4-speed, 6R RWD 6-speed13 2007 HARBOUR Consulting. All rights Segment Comparisons Top 3 #2 KokomoToledoWindsor Van DykeKokomoRWD 2007 HARBOUR Consulting. All rights American History - Total Hours Per UnitGM excludes Medium Duty. Honda and Toyota data includes partial reporting of North American Changefrom 2005( ) ( )** Nissan data estimated by HARBOUR with publicly available data


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