The DaimlerChrysler Toledo North Assembly Plant is a new greenfield site car assembly facility in Toledo, Ohio, housing new manufacturing process equipment for the 2002 'KJ' Project, located in 3 campus-style connected buildings for body weld, paint, and final assembly. BEI was involved in the design of the 516,000 s.f. body shop, and the 524,000 s.f. trim, chassis and final assembly building.  KJ is the code name for the 2002 Jeep Cherokee.

The most impressive aspect of the KJ project is the remarkable application of the DaimlerChrysler "Low-Cost Building Strategy" which dramatically reduced the comparable cost of assembly plant facilities. This strategy, which was a combined undertaking of BEI Associates, Inc. and DaimlerChrysler Corp., set out to reduce the cost of automobile manufacturing and assembly facilities, taking the traditional cost of approximately $85.00 per s.f. and reducing it to under $58.00 per s.f. without compromising the robust integrity of the building. The utilization of standardized and modular design components, as well as the attention to detail, and use of intelligent 3D CAD methods over the full scope of the work, was an important element in reducing and controlling costs. With the Toledo 2002 'KJ' program, DaimlerChrysler established new milestones in achieving the cost, delivery, and quality objectives for projects. "Construction cost targets for new assembly plants have reached a new paradigm with this project, without sacrificing integrity, maintainability and useful life," says Tito Marzotto, PE, BEI Senior Vice President and Project Director.

BEI's cost-cutting team initiated many new innovative design methodologies with the KJ program. A significant innovation introduced by this project was the extensive use of 3D modeling. Entire building systems (structural steel, mechanical piping, HVAC and electrical) for both buildings were completely and accurately modeled. The benefits of modeling included the virtual elimination of interferences (traditionally, a major cost driver), the visualization of building components, coordination, and increased productivity via 2D drawing generation.

By utilizing standardization, modularization and 3D modeling, the inevitable process layout changes, and the resulting facility additions which take place up to the last minute of design, were assimilated without change to the schedule and with reduced cost impact. In fact, beneficial occupancy was achieved three months ahead of schedule and the ambitious cost target was easily reached.  The strategy is especially evident in the conceptualization, design, detailing, fabrication and erection of the structural steel for the two buildings. The structure was designed in standard repeating modules that simplified, reduced the cost of and accelerated the time for fabrication and erection. A total of only 9 different truss types were utilized.

DaimlerChrysler has identified the 2002 'KJ' project as one of DCC's most successful new car assembly facilities.