Just curious, has anyone done the Alabama tour? I was thinking maybe I could go the week my GL is being built just for the fun of it. It's a lot cheaper and more available than Germany!

 

That would be a blast. Bring your sticks as there are some great golf courses down there - RTJ Trail.

 

I've done it twice, once when they made the original ML and again when they had the second gen ML, GL, and R on the line. If you're into cars it's certainly an interesting experience.

 

How can I find out more about the "Alabama tour" (I'm new to MB)?

 

http://www.mbusi.com/visitor-center/factory-tours

 

We went on a road trip and did the tour on Tuesday. It claims to be 2 hours, ours was just over 1. We had a new guide for the first half, the 2nd half was better.

The Alabama plant makes R Class (sold in Ca and China who ordered 6k just when MB was about to cancel the class), M, and GL. They will start C Class (US only) fall 2014 and an unnamed car fall 2015.

There is a museum and gift shop in the Visitor center where the tour starts. Steinway was the first to bring MB into USA back in 1900 and he even built a MB plant in NY, but it burnt down in 1907 and was not rebuilt.

Later after the war, it was sold via Studebaker until they went bankrupt. That's when MB USA was formed. My dad saw his first MB when he bought a Lark - leading to his legacy of MB cars (that were always surprises/shock to my mom).
Lots of different history time lines to read - design, racing, MB company,....

The tour starts on time. You get a radio receiver and headphones so you can hear the tour guide in the plant. Of course, safety glasses. A bus takes you to the plant and the safety engineers watch you as you parade in to make sure you meet the safety requirements. A safety engineer is on the tour to supervise.

The plant includes a health center, teamwear shop, cafeteria, and I think they said day care. All employees wear team wear - no matter what role.
You pass open offices behind glass. NOTE: the plant is an assembly plant. All materials/parts are on the floor for that day's work (just in time). Engines and transmissions come from Germany. Just imagine the precision in planning/provisions to make that happen.

The first station is robots that place, measure and weld the body from pre stamped steel from suppliers. The welded car is moved down to be sanded. Robots are big and work in a constant flow manner - different robots have different jobs - position, measure, weld.

People inspect and finish sanding.

The car is moved to paint. We didn't get to see that and the (new) tour guide had little to say as we walked down past the 'Green Mile' wall.

We go in to the "Marriage" line where painted bodies are 'married' to the chassis. We also saw the line where the seats were installed. There, people swing hoist/boom tools to pick the seats off the belt on one line and swing into the car on another line. Somehow, the right seat there for the right car.

We also saw the final step where the cars are closed up and started. Stations are in 90 sec intervals. Any issue, the team member pulls a yellow cord that plays a tune (not really an alarm) so the team leader can get involved. Signs displaying status are in each area.

From there, cars go to be tested on belts and systems that reminded me of the old 'safety lane' like lines. Some cars are selected to test on the outside track which according to the site is more about off road testing. The faster AMG cars may be taken to Talladega for testing.

I could see GL400 and GL500 models - cars for non-USA markets. Also interesting that ML, GL, and R cars seem to be intermingled - not separate lines as I might have expected.

You can read the mbusi site to read about their quality control processes. It's very open and clean - in order to drive quality and safety. Lots of other good info on the website.

They complete ~700 cars a day. They run 24 hour shifts weekdays, off holidays and weekends. A car typically takes 34 hours to build. Day shifts alternate early and late. Night shift is dedicated to that shift.

One dealer told them that 90% of their cars (made in Alabama) were pre-ordered so our guide suggested that meant 90% of what they make are customer spec'd.

They are already hiring for next fall with expanded C Class manufacturing. I think he said they had 11k job applications.

My GL550 is scheduled for Friday so my trip was pre-build inspection!

I wish it covered the painting and we could see more of the lines, but it was a long walk as it was. They do tours on Tuesday & Thursday. I highly recommend it if you are in the area or looking for a road trip.

On our tour was a group from Alabama Power & Light. I saw a family of 5 in the next tour and couple from Germany.

 

Great review Cincy8, I would love to visit the factory if it was within a 3 hour drive! love the 5 dollar tour fee!

For those like myself that can not visit the plant!

 

Interesting. I was hoping you would say that then you went on a race track or at least an off-road track to test a car similar to what you ordered. That's what I did for my BMW in SC. And then you would get your car presented to you in a separate room with an instructor going over all the features with you for two hours before you drive off.

Otherwise I'm not sure I would want to make the trip just to see the production and not even pick up the car unless I lived really close.

 

I would have liked to have said that! After I got there, I wondered if there were such options. I didn't know about that with BMW either (currently drive a '07 4.8i X5 that was ordered).

 

I'm sure they will start offering this soon. BMWs delivery program in SC is very popular. They pay for your hotel stay and meals and pick you up at the local airport. All day event with professional racing instructors.