goneskiian Posted June 25, 2004 Share Posted June 25, 2004 OUCH! :lol: :lol: Link to comment Share on other sites More sharing options...
SIAsensei Posted June 25, 2004 Share Posted June 25, 2004 Some points from the SIA Plant. Each engine is vacuum checked as it is assembled. After final ENGINE assembly they are run up to temp on an engine dyno and computer checked for go no-go. After final VEHICLE assembly, the cars go to inspection, where the engine dyno is just one of the many checks. The associate (we are not plant workers) hooks up the vehicle to a computer, and runs through a menu of checks that include driving through all the shift points. 100 mph would be out of bounds for a shift point. In last gear, auto or manual, the cruise control is tested for a stable hold at about 55 to 65 MPH. Several of the cruise cutouts are tested, and the computer records the go no-go condition. The the braking is tested and the dyno stops, and reverse is tested. Then driven off to the under vehicle inspection. We have had some (very few) fires from the exhaust heat at this point. Link to comment Share on other sites More sharing options...
outahere Posted June 25, 2004 Share Posted June 25, 2004 [quote name='SIAsensei']................. We have had some (very few) fires from the exhaust heat at this point.[/quote] Subarus starting on fire during a dyno run?? What is burning? :o :o Link to comment Share on other sites More sharing options...
Dr. Zevil Posted June 25, 2004 Share Posted June 25, 2004 [quote name='SIAsensei']Some points from the SIA Plant. Each engine is vacuum checked as it is assembled. After final ENGINE assembly they are run up to temp on an engine dyno and computer checked for go no-go. After final VEHICLE assembly, the cars go to inspection, where the engine dyno is just one of the many checks. The associate (we are not plant workers) hooks up the vehicle to a computer, and runs through a menu of checks that include driving through all the shift points. 100 mph would be out of bounds for a shift point. In last gear, auto or manual, the cruise control is tested for a stable hold at about 55 to 65 MPH. Several of the cruise cutouts are tested, and the computer records the go no-go condition. The the braking is tested and the dyno stops, and reverse is tested. Then driven off to the under vehicle inspection. We have had some (very few) fires from the exhaust heat at this point.[/quote] Kickass! More knowledgable people. I assume that you will be another resouce for us to bother :D ? Stick around.. we can use all the resources we can get! Thanks for the info! Link to comment Share on other sites More sharing options...
B4_Maniac Posted June 25, 2004 Share Posted June 25, 2004 [quote name='SIAsensei']Some points from the SIA Plant. Each engine is vacuum checked as it is assembled. After final ENGINE assembly they are run up to temp on an engine dyno and computer checked for go no-go. After final VEHICLE assembly, the cars go to inspection, where the engine dyno is just one of the many checks. The associate (we are not plant workers) hooks up the vehicle to a computer, and runs through a menu of checks that include driving through all the shift points. 100 mph would be out of bounds for a shift point. In last gear, auto or manual, the cruise control is tested for a stable hold at about 55 to 65 MPH. Several of the cruise cutouts are tested, and the computer records the go no-go condition. The the braking is tested and the dyno stops, and reverse is tested. Then driven off to the under vehicle inspection. We have had some (very few) fires from the exhaust heat at this point.[/quote] Thank you for posting. It was a great post. This is exactly the proccess I saw at Fuji Heavy Industries plant in Gunma. I toured this plant with the plant manager in 98. It was a jaw dropping experience. Can you release to us any dyno numbers? Can you tell us how much HP its making to the wheels and to the fly wheel? B4_Maniac Link to comment Share on other sites More sharing options...
SIAsensei Posted June 25, 2004 Share Posted June 25, 2004 The Legacy and Outback engines for 05 might look the same, but they've undergone extensive modifications. More power, stronger, lighter, quieter and more fuel efficient. The "Summer 2004" edition of "Drive", the magazine from Subaru has a good spread on the changes. We are currently only making 4 cyl. engines here. Do I sound too much like a salesman? :oops: We are shutting down today for the next two weeks to update the plant. :) I'll be back in July with a short list of changes. Link to comment Share on other sites More sharing options...
Legacy_Fan Posted June 25, 2004 Share Posted June 25, 2004 [quote name='SIAsensei']We are shutting down today for the next two weeks to update the plant. :) I'll be back in July with a short list of changes.[/quote] Interesting, is this a normal shut down period, vacations, etc.? Do you know what the are changing or updating? This may be when they tweak everything for perfection. Thanks for your inside input. Link to comment Share on other sites More sharing options...
SIAsensei Posted June 25, 2004 Share Posted June 25, 2004 B4_Maniac, I'll check with the "In Process Controls" (IPC) folks and get some real numbers. I do know that our goal is to exceed what is "the standard" if a 2.5l is susposed to get 155 HP we won't let one get through that dosen't meet that standard. I'm having difficulty getting anyone in "Engine Assembly" to answer. :cry: It is shift change on Friday, and this is everyones last day for 2 weeks. :D "Sampling" may have something, let me check there. Bad day and time. Everyone is quickly leaving. Not to worry, we built ahead for this shutdown. Lots of cars shipping. I'm going to have to strech this thread to July, sorry. Link to comment Share on other sites More sharing options...
Drift Monkey Posted June 25, 2004 Share Posted June 25, 2004 [quote name='B4_Maniac']HEY! Never judge a man by the lenght of his post! Even if it is as short as Drift Monkey's.. :P[/quote] If posts relate to manhood, then people with some of the more extensive posts may be trying to make up for some things... :?: Link to comment Share on other sites More sharing options...
SIAsensei Posted June 25, 2004 Share Posted June 25, 2004 Legacy-Fan, We take two breaks each year. Two weeks over Christmas/New Years, and two weeks over 4th-of-July. Maintenance and Engineering stay around over these shutdowns to make updates and repairs to the plant. We have been upgrading to a "Flexable (sic) Manufacturing" system. Now that Isuzu is moving out, we need to have more capacity for various and different models. Our immediate plan is for 05 Legacy, Outback and Baja. They are making some improvements in the "Paint" Department. Going to more robots. This is the only update I'm involved with at the moment. I'm sure the "Body Assembly" Department is making some repairs too. No major news here. Link to comment Share on other sites More sharing options...
B4_Maniac Posted June 25, 2004 Share Posted June 25, 2004 Awsome, I have questions about the paint proccess. Subaru paint is notoriously thin, were there any improvements made to increase the quality and thinkness of the paint? Also, in the Gunma plant, assembley workers had workstations and little "Part Robots" that moved from station to station delivering parts. Is that employed at the SIA plant? Man, I can ask questions all day! Link to comment Share on other sites More sharing options...
axis008 Posted June 25, 2004 Share Posted June 25, 2004 Thanks for providing that information SIAsensei! Good to know. Hope you have a good vacation. I can't wait till you get back and provide more info. :D -ben Link to comment Share on other sites More sharing options...
Ken S Posted June 25, 2004 Author Share Posted June 25, 2004 SIAsensi, Thanks for information! I knew someone would come through with actual facts. That 100mph on the dyno seemed a little outrageous. I hope you can hang around and answer some questions for us! Ken Link to comment Share on other sites More sharing options...
SIAsensei Posted June 25, 2004 Share Posted June 25, 2004 B4_Maniac, Out in the "Trim and Final Assembly Plant" there are several motorized robot material delivery units. Last time I checked, the front suspension on the Isuzu was delivered this way. Some of the engine assembly is moved by similar robots. The finished engine is moved from the engine assembly line to the "Run up" booth, and then to the "Hotel" storage area. I'm not sure, now, but the Subaru exhaust assembly was moved this way for a while. Lots of changes this year. I'm securing my work area now, and putting the "Vacation" message on my phone mail. I won't be back until the 12th of July. I'll check the posting from my vacation location so I'll try to keep up. Link to comment Share on other sites More sharing options...
racerdave Posted June 25, 2004 Share Posted June 25, 2004 sensei... I'll probably get flamed for saying this, but just enjoy your vacation. No need to keep up. We'll still be here when you get back. ;) Link to comment Share on other sites More sharing options...
SIAsensei Posted June 25, 2004 Share Posted June 25, 2004 OK, I'll take the portable, and check in occasionally. :) Especially if it Rains. Link to comment Share on other sites More sharing options...
schulztt2 Posted June 25, 2004 Share Posted June 25, 2004 Based on what I have heard about the 2.5i manual gear ratios (5th - 0.78, final 3.9) the engine would be turning 4110 rpm at 100 mph. Not much over 4000. Link to comment Share on other sites More sharing options...
Ken S Posted June 26, 2004 Author Share Posted June 26, 2004 SIAsensei: Is it just the base 2.5 engine that's being made at SIA right now? When will the other engines be made there? Ken Link to comment Share on other sites More sharing options...
outahere Posted June 26, 2004 Share Posted June 26, 2004 [quote name='schulztt2']Based on what I have heard about the 2.5i manual gear ratios (5th - 0.78, final 3.9) the engine would be turning 4110 rpm at 100 mph. Not much over 4000.[/quote] But if they are truly checking the max horsepower output on each engine, then they will have to run it up to at least 5600rpm. Link to comment Share on other sites More sharing options...
eamiller Posted July 14, 2004 Share Posted July 14, 2004 Running the cars on a dyno is a fairly standard practice these days. When I toured the Corvette plant, the engine is first fired on the line (which people on the tour sometimes get to do) and some initial checks are done while the engine idles as it moves down the line. Then they do alignment, then it's off to the dyno. We watched, and they run them pretty hard to do all the finishing checks. Link to comment Share on other sites More sharing options...
AWD_Rules3830 Posted June 9, 2006 Share Posted June 9, 2006 [quote name='7stars']No VVT, but it is SOHC. It has small tweaks to bump it up 3hp from the original motor made in '99 for the 2.5 RS. The older 2.5's were DOHC, which made slightly less torque at low rpm's. It's all about potential though.[/quote] If it isn't broke dont fix it. I love my car ... basically. Link to comment Share on other sites More sharing options...
red beast Posted June 9, 2006 Share Posted June 9, 2006 [quote name='sebberry']I know this is an old thread, but I was thinking about the amount of time to build a Legacy is only 1.5 hours according to the first post. Has this been confirmed by any other sources? I was watching a TV show on how Windstar vans were made and they said it took 24 hours to assemble... Thanks :)[/QUOTE] that's because fords don't fit together properly. ford employee. [IMG]http://www.sitemason.com/files/b/bdZ2cE/hammer.jpg[/IMG] Link to comment Share on other sites More sharing options...
mach_six Posted June 9, 2006 Share Posted June 9, 2006 [quote name='sebberry']I know this is an old thread, but I was thinking about the amount of time to build a Legacy is only 1.5 hours according to the first post. Has this been confirmed by any other sources? I was watching a TV show on how Windstar vans were made and they said it took 24 hours to assemble... Thanks :)[/QUOTE] any new plants built from scratch now will be more efficient even those a few years old. If you notice that Ford and GM are closing plants lately is because they're ineffiicient and to re-tool and would cost too much and it's not feasible to shut down a working plant just to remodel it. While it wouldn't surprise me if it was true but that does seem like a long time. Link to comment Share on other sites More sharing options...
astrohog Posted June 9, 2006 Share Posted June 9, 2006 Wow, I wanna work at that Subie plant. SIAsinsei went on vacation two years ago and has not returned.....? Just found the old post and was looking forward to more info, but it just died Astrohog Link to comment Share on other sites More sharing options...
miles Posted June 9, 2006 Share Posted June 9, 2006 [quote name='sebberry']I know this is an old thread, but I was thinking about the amount of time to build a Legacy is only 1.5 hours according to the first post.[/quote] +1 Can someone who toured the SIA plant give us more information on the build time of the Legacy. Link to comment Share on other sites More sharing options...
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