Dodge Caliber sales hurt by production glitches
Chrysler Group's high-tech Belvidere, Illinois assembly plant is having trouble getting its robots to behave, and that's holding back sales of its popular Caliber model. Turns out that the welding and assembly robots are, well, running into each other, bringing the assembly line to a halt while the Swedish-built robots are straightened out.As a result, Belvidere production is about 25 percent below its target, and dealers are building up ever-growing waiting lists for the hot-selling Caliber.
With the new Jeep Compass recently added to the mix at the flexible manufacturing facility, and the Jeep Patriot waiting in the wings, Chrysler had better get the robots to behave sooner than later. This isn't a trivial problem - each ABB robot is about 15 feet tall (a typical unit is shown at right), and the Belvidere robotic body shop has more than 700 robots. Industry analysts interviewed by the Rockford Star are concerned that the problems with the Belvidere facility show that Chrysler tried to make too many changes, too quickly, and now it's paying the price.
The $419 million flexible manufacturing upgrade to the Belvidere plant is the beginning of a wholesale modernization of Chrysler's manufacturing process, with similar upgrades underway at two other assembly plants.
[Source: Detroit News]
Reader Comments (Page 1 of 3)
Robbie 1:45PM (7/25/2006)
1:A robot may not injure a human being or, through inaction, allow a human being to come to harm.
2:A robot must obey orders given it by human beings except where such orders would conflict with the First Law.
3:A robot must protect its own existence as long as such protection does not conflict with the First or Second Law.
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Robbie 1:45PM (7/25/2006)
1:A robot may not injure a human being or, through inaction, allow a human being to come to harm.
2:A robot must obey orders given it by human beings except where such orders would conflict with the First Law.
3:A robot must protect its own existence as long as such protection does not conflict with the First or Second Law.
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Ryan 1:47PM (7/25/2006)
Does anyone remember how freaking POPULAR the Dodge Neon was?! Remember it flew off the shelves faster than they could build them, it was the cure to the imports and it looked funky modern.
Yeah, Dodge Caliber, can we all hope it's built as good as a neon, by looking at these stoned robots I have been assured it is.
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Bert 1:56PM (7/25/2006)
I am welder, please insert Caliber.
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Eric L. 1:57PM (7/25/2006)
More accurately: Dodge Caliber sales hurt by the fact that its junk.
I understand the utility wagon idea (which is clever) but given that the Caliber was released later than moldy oldies like the Forester, PT Cruiser, and Matrix, and still cannot beat them in any mag comparo, is a huge disappointment.
And for anyone who thinks I'm a hater, go ahead and prove me wrong - find ONE mag comparo that shows the Caliber coming out on top.
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Hung2 2:04PM (7/25/2006)
Are they sure its just a problem with the robots? I'm sure its got nothing to do with the design/look of the Caliber itself. Or does it? Maybe the robots have developed a "soul" and have come to the realization that the Caliber is crap and thats why they keep running into each other. I'm sure there's a reasonable explanation for this.......on second thought maybe there isn't. The Caliber is crap and the robots are rebelling!!
CYBORGS UNITE!!
Hey Ryan - hows that Bimmer shopping coming along?
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Nick 2:04PM (7/25/2006)
Eric: The public doesn't agree with the magazines.
They generally don't. As soon as Consumer Reports puts a stamp of disapproval on it, like they do for every other manufacturer that isn't Japanese (hello, audi, hyundai, etc), the sales will drop off a bit.
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Robbie 2:09PM (7/25/2006)
The robots are pissed because they don't get paid 100k/year like the UAW workers down the line. They need a union!
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RickDom 2:10PM (7/25/2006)
Just because something wins a comparison doesn't mean it's the right car for every person. It stands out far more than any of the other vehicles they have compaired it do, stylisitcally or for other reasons for people and that is why they want it. Not everyone buys a car just because CR rated it high and because one of the auto magazines ranked as top in a comparison test.
And it's a small station wagon, plain and simple, just like all those other vehicles, people like to give them cute names so they feel less embarassed about buying a station wagon.
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K 2:12PM (7/25/2006)
I'm shopping and I liked the Caliber. But not enough to pay a premium and wait. And there were things that seemed weak - some trim, etc. They didn't have to happen, the cost of fixes would have been trivial. Not a good omen.
Still, I was in a holding pattern until the news about quality came in. It doesn't good. And I wanted it to be good - for DC and for the buyers.
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Ryan 2:19PM (7/25/2006)
"Hey Ryan - hows that Bimmer shopping coming along?"
-Oh man it's great, my Mazda 3 goes in next monday to get repaired. Of all things I found I'm really liking the 525i. I drove this one (see link) last week and LOVE it I have told them If I could put like $5,000 down to hold it because my "sister" is borrowing my Mazda for the week and I will come back to trade it in once "she" gets back. AKA, it's in the body shop! So they will be calling me later this week if it is OK to hold the car, just kind of stressing out because I am going certified pre-owned, but damn this car can handle!!! So hopefully in the next couple of weeks ITS MINE!!! Goodbye Mazda 3, but I do love that car too, hello BMW. Because I'm paying cold hard cash, they were able to work a better deal on "pre-owned".
What do you think of the car?! :-)
http://www.cars.com/go/search/detail.jsp?tracktype=usedcc&searchType=21&paId=203297796&pageNumber=0&numResultsPerPage=50&largeNumResultsPerPage=0&sortorder=descending&sortfield=PRICE+descending&certifiedOnly=false&recnum=25&leadExists=true&criteria=K-%7CE-%7CM-_5_%7CN-N%7CR-75%7CI-1%7CP-PRICE+descending%7CQ-descending%7CZ-89015&aff=national
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Michael Karesh 2:27PM (7/25/2006)
I should have initial reliability data on the Caliber before too much longer. Already 41 owners are signed up to participate in TrueDelta's research. There was a knocking issue, but a TSB seems to have taken care of it.
I didn't find the Caliber much fun to drive. but then there's my take on comparison tests:
http://www.truedelta.com/pieces/comparison_tests.php
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Glenn A. 2:34PM (7/25/2006)
Chrysler bought AMC and obtained a brand-new fully modern "Saturn-like" plant facility tooled up to build the "AMC Renault Premier" sedan (Taurus sized) in 1986, the French (naturally) robots worked fine. No problems. So, of course, when Chrysler retooled the plant to build the original "cab forward" big front drive cars, did they reuse the expensive 5 year old plant filled with still useable robots? Nope. Pulled every single last one out and replaced them all. So, my question - was it US taxpayers who got stiffed with the bill because Chrysler wrote the whole thing off as a tax deduction, or was it Canadian tax payers, or both?
Chrysler sure has problems with robots, don't they?
I recall a few years ago when they finally modernized the Jeep plant, the robots were not letting the Jeeps go. Literally. A robot welder had to be continually pried off the rear end of the Jeeps (no comments, now).
Finally, I guess, one of the plant managers took a sledge hammer, whacked the offending robot and had a man and a welder brought in to do the job.
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Glenn A. 2:34PM (7/25/2006)
Chrysler bought AMC and obtained a brand-new fully modern "Saturn-like" plant facility tooled up to build the "AMC Renault Premier" sedan (Taurus sized) in 1986, the French (naturally) robots worked fine. No problems. So, of course, when Chrysler retooled the plant to build the original "cab forward" big front drive cars, did they reuse the expensive 5 year old plant filled with still useable robots? Nope. Pulled every single last one out and replaced them all. So, my question - was it US taxpayers who got stiffed with the bill because Chrysler wrote the whole thing off as a tax deduction, or was it Canadian tax payers, or both?
Chrysler sure has problems with robots, don't they?
I recall a few years ago when they finally modernized the Jeep plant, the robots were not letting the Jeeps go. Literally. A robot welder had to be continually pried off the rear end of the Jeeps (no comments, now).
Finally, I guess, one of the plant managers took a sledge hammer, whacked the offending robot and had a man and a welder brought in to do the job.
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Rob 2:37PM (7/25/2006)
that 525i is hot! While I LOVE my TL and
wouldn't think of trading it in, I sure wouldn't mind if my boyfriend would get one just so I'd be
able to drive the TL one day, the beemer the next :)
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Mike 2:41PM (7/25/2006)
I just love the "comments" about the Caliber being junk.
one question here; have you driven one?
I've owned over 100 new cars, and have never once looked to any magazine to hold my hand in a vehicle purchase. many of the vehicles I've purchased were at the bottom of the heap in these supposed "expert" comparisons, and they were absolutely great cars that lasted forever.
if you did take the time to look at the Caliber, you would find a very practical vehicle for not much money. there is so much room in the driver's seat that I have to move the seat forward, and I'm 6'3". that doesn't happen in too many cars of any size or price.
and guess what? unlike the Matrix, Vibe, or VW Rabbit, I don't have to take a gruesome gray interior as my only choice.
I guess the 200+ folks that are on the Caliber waiting list at my Dodge dealer need to pick up copies of the "small timer's bible", consumer reports, to correct the error of their ways.
CR's stellar recommendations of all Volkswagen products sticks in my mind, and then they mention that their reliabiity is terrible. for those unaware, CR's chief auto engineer was the only engineer ever fired from Chrysler; is it possible that all the low ratings of Chrysler products in the small timer's bible could be related to this fact?
Mike
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ramsport47 2:43PM (7/25/2006)
#5...just because it is not leading the pack in statistics ormag comparos does not mean it's junk. It is a very solidly built and reliable car and obviously by the people buying/ordering them, alot of people agree with me
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Frank 2:49PM (7/25/2006)
And for anyone who thinks I'm a hater, go ahead and prove me wrong - find ONE mag comparo that shows the Caliber coming out on top.
Posted at 1:57PM on Jul 25th 2006 by Eric L.
Hi, I'm Eric L. and I don't think for myself. I read all the latest car mags and Consumer Reports and based on what they say I make my decisions instead of using my own brain and actually TEST DRIVING SOME CARS. Then I post smug comments on autoblog so I can feel good about myself.
Dude, Caliber is selling well because of the times (gas prices) and because it's a fresh design. What magazines say may turn you against it but obviously everyone in not leaming like you. Now if quality problems creep up like the previous Neon, then sales will fall but the car has not been around long enough yet. Until and if that happens reserve judgment, unless you think your so damn smarter than the rest of us that you can't help to give us your opinion.
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Jack of Shadows 2:57PM (7/25/2006)
Where is the Terminator when you need him?
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JJ 3:07PM (7/25/2006)
Yeah at the dodge dealership i work at we cant keep this things in stock, its crazy how fast we sell them, sure they're not for everyone (no car is), but those that buy them, like them as you get a lot of car for not a lot of money and its new, gets good MPG, and performs reasonably well for a sub 18k car.
Heck if i wasnt a slave to my charger... i may even drive one. =)
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