Cars rolling off the assembly line at Kia

WEST POINT, Ga. — It’s no longer months or weeks until Kia Motors Manufacturing Georgia starts production of the 2011 Sorento.

It’s now days.

Cars have been rolling off the assembly lines for weeks now, but the official start of production is still mid-November, said Randy Jackson, KMMG director of human resources and administration.

That’s what Kia officials have said since the Korean auto manufacturer announced its plans to locate its first American manufacturing facility in West Point back in March 2006.

KMMG opened its doors this week to introduce the national media to the plant and the 2011 Sorento. On Thursday, press representatives from various Web sites and magazines viewed the training center, which is down Kia Parkway from the plant, and the plant itself. The public has not been allowed to tour the plant yet, but officials say they will be offered the chance in the future.

The one part of the plant that was completely off-limits to the group was the paint shop. Danny Gordon, who works in stamping, said the environment of the paint shop is so delicate, even the employees that work there can’t wear certain deodorants or colognes because it could adversely affect the paint process. They must wear lint-free suits and caps, he added.

Kia’s largest piece of the production puzzle is located in stamping. The 135-ton piece is a key component of a 5,400-ton transfer press that stamps steel into 17 different types of vehicle panels. Gordon said the massive machine, situated roughly 20 feet below ground and more than 25 feet above ground, can complete up to 15 parts per minute. On Thursday, it was doing 10.5, he said.

The high ceiling in the welding shop not only accommodates large equipment pieces, but also an overhead conveyor system, which Gordon said helps eliminate floor traffic or the potential for accidents.

The technological advancements that Kia is so proud of are most obvious in the welding shop, where 244 robots operate with precise movements to connect pieces in the shape of a car.

But it’s in general assembly, where employee Gary Parker said “it all comes together.” After a vehicle passes all the quality checks in welding and then in painting, it moves along another overhead conveyor system, that connects the two buildings, to the assembly plant, where workers install everything else to complete a Sorento.

This is another area, besides welding, where Kia installed wood floors to be ergonomically-friendly to employees. Parker said machines along the assembly line raise and lower vehicles, and the various parts so workers don’t have to bend or strain to do their job.

In about a minute, a handful of workers were able to attach a transmission, motor and exhaust system to a black-painted chassis before it moved along the line for another part.

When a vehicle gets to the “nursery,” Parker said it gets its keys and some fluids. Then it’s ready for more quality testing, including a roll test, where the vehicle reaches up to 80 mph in a closed room before the brakes are applied forcefully. During a shower test, Parker said it is “flooded” with water to make sure there are no leaks.

Parker said such tests are repeated over and over until a vehicle passes them all completely. Then it hits the road, a 2-mile test track, located behind the plant buildings for more tests. Not just anyone gets to do the test driving.

In fact, Kia employees say those people who do the driving are specially attuned to listen for anything and everything that might be wrong with the vehicle. Jackson said no vehicle will leave the lot unless its quality is 100 percent guaranteed.

The Sorentos that are rolling off the line now will have reached that standard, but Parker said they will likely be used for show, rather than sales.