AMS: What addition was most recently introduced to the plant?

　　Grant McPherson (GM): The building where the Jaguar XK is and F-TYPE will be assembled has received a canopy extension to allow room for the F Type and XK to share the same build facility.

　　A new framing station has been integrated into the existing Jaguar XK body assembly facility, enabling the Jaguar F-TYPE to share the production area, tooling and equipment – 26 new robots have been integrated with the current Jaguar XK assembly facility to be used on both models.

　　AMS: What are the current challenges (pinch points) in production?

　　GM: The biggest challenge at Castle Bromwich is a highly ambitious new model programme, which sees the plant carrying out back-to-back new model launches while maintaining the high standards of quality the customer demands.

　　AMS: What aspects of the production process are unique to Jaguar?

　　GM: The key process which really sets us apart from other manufacturers, particularly in the UK, is our advanced aluminium body construction.

　　AMS: How have you built fl exibility into the production lines/processes?

　　GM: Jaguar Land Rover needs to remain fl exible to changes in customer demand. Over and above our existing fl exibility, including voluntary overtime, we have recently introduced arrangements to deliver Assured Saturday Working for a limited number of Saturdays per year. This allows the plant to react to customer needs quickly.

　　AMS: What are the current levels of automation (% of production/assembly operations) at the plant?

　　GM: It is diffi cult to put a percentage on this. We have over 330 bodyconstruction robots in our press and body in white areas. All of our trim and fi nal operations, with the exception of screen glass mounting, are carried out manually.

　　AMS: Will this number be increased in the future. If so, in what area?

　　GM: We continue to look at how our processes can be improved and how technology can support this.

　　AMS: In what (production related) area will future investment be made?

　　GM: Jaguar Land Rover has ambitious plans for growth and this includes investing in its manufacturing facilities.

　　AMS: How much of the production at Castle Bromwich is for export?

　　GM: 80% of Jaguar Land Rover products are exported.

　　AMS: What strategies/technologies are employed to reduce energy consumption and minimise environmental impact?

　　GM: There are a number of technologies employed at Castle Bromwich to reduce energy consumption and minimise impact upon the environment. These include:

　　• Factory Management System (FMS), which automatically operates lighting within the plant.

　　• On-site heat and energy power plant which recycles the heat generated across the plant.

　　• Inverter devices on all medium and large motors which allows us greater control of energy use as oppose to motors all running at a single speed.

　　• Fully-automated monitoring system to monitor energy use across theplant.

　　We are looking for ways in which we can reduce energy consumption when we are not building cars, as well as during full production.

　　bonding is automated, there are a number of stages where riveting and bonding require manual operation. This indicates the volume of production which allows this almost‘handmade’ approach. It should be noted that this isn’t a reluctance to embrace new technologies but rather opting for the process that works best for the application. The lower volume of completed XJ BIWs per day contrasts with the production volumes of steel, welded mass produced vehicles.

　　It also highlights one of the reasons for the limited number of all aluminium models on the market; the production process is slower than producing spot welded, steel vehicles.

　　An ABB robot cell performs three hemming and clinching operation for boot lids, bonnets and front wings, but these parts are then fitted to the body manually to ensure correct gaps are achieved. Given the prestige segment Jaguar’s cars occupy, quality control is a high priority. Perceptron vision systems are used throughout the bodyshop tp provide accurate quality checks. Again the doors are hung on the body and adjusted manually. Special weights are placed in the doors to simulate the weight of glass, trim and electrics to be fitted at final assembly, ensuring a perfect door gap and fit at that stage.

　　Diversification of specification Before leaving the bodyshop for painting the bodies pass through a highlight inspection bay where operatives wipe a highlighting fluid over the body to reveal any damage to the panels that might need reworking prior to painting.

　　After painting, the bodies are sent to a marriage line where the powertrain and suspension are fitted. The wiring looms are stored in a preheated unit on the lineside which makes fitting the looms easier. Although the volumes are not high the levels of customisation are, with a number of engine, trim and equipment options available – and with a high number of vehicles for export, the diversification of specification increases.

（AMS）