Pilot cars ...

[Keith Seymore]

Originally Posted by Keith Seymore

Current production build would continue at the present line rate; the future model year pilot builds would be introduced one at a time, and perhaps with an empty carrier in front of and behind the special build. The new model launch team (engineering, mostly) would follow the build through the process making note of any issues or problems for resolution. There is, of course, cross pollenization and sharing of learnings between the various assembly plants as well, as the model year is rolled out.
K

A couple quick thoughts about model change over:

Usually the assembly line at a particular plant will shut down completely for retooling or upgrades, as one would expect. This is fine, because you start with the "lead plant" first, and the other plants continue to produce the current model until it is their turn, so you still have product in the field to sell.*

However, if there is not a lot of product change the program team can elect to do a "rolling model change". The line does not shut down and the new model follows right after the current model, sometimes with an empty carrier but sometimes not even that. During the squarebody era there were a couple changeovers where the only difference was the new truck had a handmade paper sign taped to the windshield; that was the only difference discernable to the assembly line workers.

There were a couple occasions were the VINs didn't even start over; they just continued to ratchet up sequentially based on the prior year's starting point.

K

*That is what is so remarkable about Henry Ford's transition from the 1927 Model T to the 1928 Model A. Ford shut the Highland Park plant down cold while they designed and tooled the new model at the Rouge. It was quite the media sensation when the Model A was finally introduced.