Plant small but efficient

Press, 26 August 1977, Page 8

Plant small but efficient

Compared with most car assembly plants in New Zealand, the Subaru plant at Waitara is relatively small, covering only 53,000 sq ft. Another company in the Motor Holdings group, Motor Components, Ltd, also occupies a portion of the factory. The relatively small scale of the Waitara operation has advantages, according to the company. The labour force is stable and there is a real sense of identification with the end product. At Waitara every member of the staff feels responsible for quality of assembly and the company believes this will be evident in the high standard of assembly of the Subaru.

The Waitara plant was first used for the production of farm motor-cycles. Local manufacture of these machines became uneconomic in 1973 when the company decided to use the plant for the assembly for four-cylinder cars.

Through its subsidiary, Motor Components, Motor Holdings has a long connection with the town. The necessary skilled tradesmen were available and most of the installation of assembly line equipment was done by existing Motor Components staff. The 30 spot-welding machines at the Waitara plant were made in the Motor Components machine shop, the only boughtin parts being transformers and electronic timers.Motor Components staff also made the “body grip” hoists, and the various stillages racks and trollies used in the plant. This policy allowed the company to build up a core of staff before the first cars were assembled in December, 1974. It also made the plant less dependent on outside firms for the supply of special tools and equipment used in the assembly of future models. The Waitara plant was custom built for the assembly of four-cylinder cars, so it was possible to incorporate many new concepts in the design.

spection system was rejected in favour of the “self-inspection” system used by Volvo and other small volume quality car manufacturers. Assembly tasks are done by teams of three employees, each member of the team taking it in turn to inspect the work of others. This system is said to improve assembly quality and make work at the plant much less monotonous. More than 4500 cars

and station waggons have been assembled at Waitara for. companies in the

Motor Holdings Group and under contract to other importers.