The Story of Detroit Assembly Complex – Mack (Video Tour)

An employee at the Detroit Assembly Complex - Mack checks the paint finish for imperfections on a Jeep Grand Cherokee L.

We are proud to build the all-new, three-row Jeep® Grand Cherokee L in the heart of the Motor City. With an investment of $1.6 billion, we converted two existing facilities and added another in less than two years to create Detroit Assembly Complex – Mack, the first new automotive assembly plant to be built in Detroit in 30 years. Explore the plant with a virtual tour that highlights the making of the all-new Jeep Grand Cherokee L.

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Plant Overview – Hear the story of our 100-year history on the Mack site.

  • More than 100 years of manufacturing on Mack site
  • First new assembly plant in the city of Detroit in 30 years
  • Investment: $1.6 billion (announced February 2019)
  • New jobs: 3,850; commitment to putting Detroiters first in the application process
    • 2,100 Detroiters have filled the new positions
  • Construction: Began in Q2 2019; completed in less than two years
  • Total floor space: 3 million square feet
  • Acreage: 266
  • Operating pattern: Three shifts, five days per week
  • Employment: ~4,900
  • Total production time: ~36 hours
  • Three main production facilities: Body Shop, Paint Shop and General Assembly
  • Logistics: 770 inbound trucks per day; 76 trucks and 95 railcars outbound per day

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Body Shop (Body in White) – Our new 3 million-square-foot assembly plant in Detroit consists of three separate facilities: body shop (Body in White), paint shop and general assembly. Let’s take a look inside the body shop, where the vehicle begins to take shape.
  • Building: Formerly Mack Engine II; idled in 2012
  • Floor Space: 650,000 square feet
  • Robots: 578
  • Production time: 2 hours

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Paint shop – Take a look inside the facility where a new three-row, full-size Jeep SUV and next-generation Grand Cherokee, as well as their electrified models, will get their beautiful, long-lasting paint finishes.
  • Building: All-new facility
  • Floor Space: 800,000 square feet (five floors)
  • Robots: 124
  • Production time: 12 hours
  • Colors: 11
  • Process: Fully automated; 100 percent robotic spray application
    1. Phosphate E-coat: first layer of corrosion protection
    2. Sealer: 28 robots; ~208 feet of sealer applied per car to prevent leaks, corrosion and wind noise
    3. Primer: 8 robots; provides smooth base layer and enhances paint durability
    4. Base paint coat: 21 robots (10 painting and 11 “opening”)
    5. Clear coat: final protective coating
    6. Finesse and polish: identify and remove any imperfections to ensure smooth paint finish

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General Assembly – General Assembly is where we install vehicle components: seats, instrument panels, wheels, etc. This is the final step in the assembly process before a vehicle is shipped to the customer.
  • Building: Formerly Mack Engine I; built the Pentastar engine family until December 2019
  • Floor Space: 1,000,000 square feet
  • Stages: Trim, Chassis, Final
    o Trim: Installation of sunroof, wiring harness, major electrical, instrument panel, and windshield, rear and half glass
    o Chassis: Engine dress; engine and chassis marriage; body and chassis decking; hose and electrical connections; fluid fill and functionality testing
    o Final: Installation of seats, steering wheel, major components; doors hung; wheels and tires; electrical test
    – Final validation: Aligners, headlight aim, rolls, ADAS (Automated Driver Assist System); BSR test track; inline water test; certification line
Detroit Assembly Complex - Mack Facts & Figures
Stellantis (NYSE: STLA) is one of the world’s leading automakers and a mobility provider, guided by a clear vision to offer freedom of movement with distinctive, affordable and reliable mobility solutions. In addition to the Group’s rich heritage and broad geographic presence, its greatest strengths lie in its sustainable performance, depth of experience and the wide-ranging talents of employees working around the globe. Stellantis will leverage its broad and iconic brand portfolio, which was founded by visionaries who infused the brands with passion and a competitive spirit that speaks to employees and customers alike. Stellantis aspires to become the greatest, not the biggest, while creating added value for all stakeholders, as well as the communities in which it operates.

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