DETROIT, March 31, 2020 /PRNewswire/ -- As the
COVID-19 pandemic spread across the country, it created a critical
shortage of face masks. To help protect workers in essential
services across the country, GM launched a rapid-response project
to produce masks at scale on Friday, March
20. Seven days later, the team had produced their first
sample on the new production line.
By next week, GM expects to deliver its first 20,000 masks to
frontline workers.
Without help from GM's partners around the globe, the project
would have taken several months to plan and execute. The team
working on GM's face-mask project accomplished the task in just one
week.
"Our team began looking at ways we could quickly utilize our
talents and resources to help in the shared fight against
COVID-19," said Peter Thom, GM vice
president, Global Manufacturing Engineering. "Working around the
clock, our team rallied with incredible passion and focus to come
up with a plan to produce masks that will help protect the women
and men on the front lines of this crisis."
Project kickoff to first mask in six days, 23 hours, 30
minutes
At 3 p.m. on Friday, March 20, the
core team assembled for the first time, kicking off the project and
starting the timer.
"Because we wanted to move fast, the team set an incredibly
aggressive goal: To have the production line up and running tests
within a week," said Thom.
More than 30 engineers, designers, buyers and members of the
manufacturing team were asked to help with product development,
sourcing materials and equipment, and planning the production
process.
"The first people we called were those who work with fabric
vehicle components," said Karsten
Garbe, GM plant director, Global Pre-Production Operations.
"In a few days, the company's seat belt and interior trim experts
became experts in manufacturing face masks."
The team sourced the necessary raw materials by leveraging GM's
existing supply chain. These materials include metal nose pieces,
elastic straps and blown, non-woven fabric filter material.
Simultaneously, GM collaborated with JR Automation in Holland, Michigan and Esys Automation in
Auburn Hills to design and build
the custom machinery needed to assemble the masks.
For the project, the team selected the ISO Class 8-equivalent
cleanroom at GM's manufacturing plant in Warren. Work began at the
Warren facility by removing existing equipment from the cleanroom.
The team cleared approximately 31,000 square feet to accommodate
the mask production lines. Crews then installed new electrical
service lines to power the production equipment and assembly
stations.
With the site cleared and prepped, production equipment and
materials were then delivered to the Warren facility. Crews worked
around the clock to install equipment and stage the production
line. The team then tested each step in the production process,
looking for opportunities to improve quality and production
speed.
At 2:30 p.m. on Friday, March 27,
the project team had their first production-made mask in their
hands.
"Not only did the team make their goal, but they
over-delivered," said Thom. "They actually beat our deadline,
running the first mask through the equipment 30 minutes ahead of
target. We're excited because this means we're even closer to being
able to protect the healthcare teams who are working tirelessly to
save lives."
20,000 masks expected to be delivered on April 8
The projected production volume is just as aggressive as the
project's timeline. By Monday, March
30, more than 2,000 masks were produced by teams working
through the weekend. These initial test samples will be used to
ensure the quality standards are met. Once these quality measures
are completed, the team expects to start producing masks for
delivery early next week.
GM and the UAW will seek more than two dozen paid volunteers
from Detroit-area plants to staff
mask operations. In addition, GM has implemented a series of safety
measures to protect these team members through physical distancing,
enhanced on-site cleaning and pre-entry health
screening.
The team expects to have 20,000 masks ready for delivery on
Wednesday, April 8. Once the line is
running at full speed, it will be able to produce up to 50,000
masks every day – or up to 1.5 million masks a month. GM is
currently developing a plan for distributing the masks, including
using some of this important safety equipment to protect employees
in critical GM operations.
For more information on General Motors' efforts to combat the
COVID-19 outbreak, please visit
https://www.gm.com/coronavirus.html
General Motors (NYSE: GM) is a global company
committed to delivering safer, better and more sustainable ways for
people to get around. General Motors, its subsidiaries and its
joint venture entities sell vehicles under
the Chevrolet, Buick, GMC, Cadillac, Holden, Baojun and Wuling brands.
More information on the company and its subsidiaries,
including OnStar, a global leader in vehicle safety and
security services, and Maven, its personal mobility brand, can
be found at http://www.gm.com.
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SOURCE General Motors Co.