Jasper Engines and Transmissions has expanded its gas engine remanufacturing division within the Jasper, Ind., facility.
The Jasper facility utilized four remanufacturing lines (called PODs), in which an engine went from a core to a finished product within one remanufacturing unit, according to a press release. Each POD has specific engine families that it remanufactures.
The need for a fifth POD was realized as early as November, 2013, as increased sales of Jasper remanufactured Ford modular engines (4.6- and 5.4-liter Triton V-8 and 6.8-liter V-10) exceeded the Gas Engine Division’s maximum production, the release noted.
“We were selling 28 units per day at the start of the year,” said Randy Bauer, Jasper facility gas division manager. “We’re currently averaging 33 sales per day of these units.”
The new POD, named POD 305, began gas engine remanufacturing on June 1 after months of development, and the relocation of Jasper’s differential division, according to the release. A team of associates handles engine remanufacturing duties within five areas: disassembly, prep and repair, head machining, block machining and assembly/testing.
“We were spending a considerable amount of overtime to produce these units,” Bauer said. “With this engine family remanufactured in a separate POD, we’ll reduce the amount of overtime that our associates are working, and at the same time improve the ergonomic part of their work.”
The POD expands on an open concept method used in other areas within the gas division.
“We had open floor space available to configure each department in a U-shaped design,” said Bauer. “We found this design to be very successful in the disassembly and assembly areas in our other PODS, so it was used in each area of 305.”