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Sterling Heights Assembly

The Sterling Heights Assembly Plant (SHAP) is a major automotive assembly facility in , operated by , specializing in the production of Ram 1500 pickup trucks and preparing for battery-electric variants. Spanning 5 million square feet on 286 acres at 38111 Van Dyke Avenue, it employs advanced processes, including a Gold-certified body shop and one of the largest LED lighting retrofits in the industry with 12,000 LEDs. Originally constructed in 1953 as the Michigan Ordnance Missile Plant for the U.S. Army, the site produced jet engines and ballistic missiles under 's management during the era. In 1980, converted it into an automotive assembly plant, but acquired it in 1983, repurposing it for vehicle production. Over the decades, SHAP has manufactured a range of , , and models, including the LeBaron GTS, Stratus, and sedan, before shifting focus to light-duty trucks. Since March 2018, it has exclusively assembled the 1500 (DT generation), producing Quad Cab and Crew Cab configurations across ten trim levels, such as the , , and off-road-focused RHO. The plant reached a significant milestone in April 2025 by assembling its two millionth Ram 1500, a Flame Red 2025 RHO model, just seven years after initial production began. Represented by United Auto Workers Locals 1700, 889, and 412, SHAP's workforce supports high-volume output with thousands of customizable options per truck. Recent investments underscore its evolution toward electrification: a $1.48 billion retooling in 2016 enhanced Ram 1500 capabilities, followed by $235.5 million in 2024 for multi-energy production, including the 2025 Ram 1500 REV (battery-electric) and Ramcharger (range-extended hybrid). These upgrades position SHAP as a key hub in Stellantis' strategy for sustainable mobility, with the facility set to become the first in the U.S. to build fully electric Ram 1500 trucks.

Plant Profile

Location and Infrastructure

The Sterling Heights Assembly Plant is situated at 38111 Van Dyke Avenue in Sterling Heights, Michigan, United States. The facility spans 286 acres (116 ha) and includes 5,000,000 square feet (460,000 m²) of manufacturing space. Key infrastructure elements comprise a 1 million square-foot that is LEED Gold certified, a 425,000 square-foot state-of-the-art paint shop, and general assembly areas designed for high-volume vehicle production. Adjacent stamping facilities support operations, distinct from the nearby Sterling Stamping Plant. The plant's location provides access to major highways including I-94 and M-59, along with proximity to Metropolitan Wayne County Airport approximately 35 miles away, enhancing logistics and supplier connectivity within the Stellantis North America network.

Capacity and Workforce

The Sterling Heights Assembly Plant, operated by , has an annual production capacity of up to approximately 350,000 vehicles following a major retooling in 2016 to focus on Ram 1500 pickup trucks. This capacity was demonstrated in 2019 when the facility produced 345,000 Ram 1500s, reflecting its high-volume output potential under optimal conditions. As of 2023, the plant employed approximately 7,000 workers, the majority of whom are unionized members of the (UAW), supporting its role as one of ' largest U.S. facilities. Subsequent layoffs in 2024, including nearly 200 workers in September and an additional 42 in October, reduced staffing levels. Employment peaked at similar levels during earlier car production eras, such as the assembly of the sedan before the 2016 transition, though current staffing aligns with the demands of truck . In October 2025, announced a $13 billion investment plan to expand U.S. capacity and add over 5,000 jobs across its facilities, potentially benefiting SHAP. To achieve its production targets, the plant operates on a three-shift around the clock, a structure implemented in January 2021 to maximize efficiency and output. This 24/7 operation enables continuous assembly processes, with shifts rotating to maintain workforce sustainability. The facility emphasizes advanced integration in its and assembly lines, which has significantly reduced manual labor risks by automating heavy lifting and repetitive tasks. For instance, extensive use of robotic systems for frame handling and minimizes worker exposure to hazards, contributing to improved overall . While specific OSHA compliance records highlight ongoing inspections and minor incidents, the plant maintains a focus on regulatory adherence through these technological enhancements. programs, including simulators for equipment operation like forklifts, further support worker and skill development.

Historical Development

Origins and Early Operations

The Sterling Heights Assembly Plant was established in 1953 by the Chrysler Corporation as a defense facility during the era, initially serving as a jet engine production site for the U.S. Army under the operation of the Michigan Ordnance Missile Plant, with acting as the primary contractor. The plant focused on manufacturing components for ballistic missiles, including the and models, reflecting the heightened demand for technology amid geopolitical tensions. In 1980, amid a strategic shift toward automotive in , the facility was sold to of America, which undertook its conversion from missile production to an automobile assembly operation intended for small car manufacturing. This adaptation involved reconfiguring the site to accommodate vehicle body construction, including the installation of stamping and lines to support automotive body-in-white processes, marking a significant pivot from to mass-market car production infrastructure. However, due to a subsequent sales downturn, did not commence vehicle assembly at the plant before divesting it. Chrysler Corporation repurchased the facility in 1983 for $192 million, resuming automotive operations and emphasizing production to bolster its lineup in the competitive small-vehicle segment. Production began in September 1984 with models such as the GTS and , and by the end of the 1991 model year, the plant had assembled nearly 1.3 million units, establishing its role as a key hub for Chrysler's compact offerings. This period solidified the site's transition, with ongoing refinements to welding and assembly lines enhancing efficiency for automotive output.

Expansion and Challenges

In the 1990s, Sterling Heights Assembly shifted toward greater production of mid-size sedans, including models like the and , which helped bolster the plant's output amid Chrysler's platform-sharing strategies for compact and mid-size vehicles. This period marked a strategic expansion to meet growing demand for family-oriented sedans, with the facility adapting its lines to support these vehicles starting in the mid-1990s. By 2006, Chrysler invested approximately $500 million across its Sterling Heights operations and adjacent stamping facilities to modernize automation and enhance manufacturing flexibility, enabling the plant to produce updated versions of the Sebring and Stratus convertibles and sedans with improved efficiency. This upgrade focused on robotic systems and overhauls, positioning the facility for more versatile assembly processes in response to evolving market needs. The 2008-2009 severely threatened the plant's viability during 's filing in 2009, when it was slated for closure as part of the restructuring plan to eliminate excess capacity, with operations projected to end by December 2010. The facility's survival hinged on concessions, including wage reductions and benefit adjustments, alongside a U.S. government bailout providing $12.5 billion in loans that enabled the "New Chrysler" to emerge from Chapter 11 in June 2009. In February 2010, the restructured Group repurchased the idled plant outright from Old Carco LLC—the remnants of the bankrupt entity—for $20 million, securing its future and retaining about 1,200 jobs. The introduction of the in 2011 became pivotal for sustaining operations, with the all-new model launching at Sterling Heights and helping the plant add a second shift while building on the prior Sebring platform. continued through 2016, peaking at around 178,000 units sold annually in , which underscored the sedan's role in stabilizing the workforce and output before the facility transitioned to truck manufacturing.

Transition to Truck Production

In July 2016, (FCA) announced a $1.48 billion investment to retool the Sterling Heights Assembly Plant for light-duty truck production, shifting focus from sedans to meet rising market demand for SUVs and pickups. This strategic pivot involved a phased shutdown, beginning with the cessation of sedan production in December 2016 to allow for facility transformation. Retooling efforts, which occupied much of 2017, included upgrades to assembly lines, , and systems to support truck manufacturing. The plant resumed operations in early 2018, with the first next-generation 1500 rolling off the line in March as a 2019 model year vehicle. The transition enhanced the plant's role within FCA's (later ) network by enabling production of advanced truck features, including optional systems for improved ride quality and the eTorque mild-hybrid system for better and performance. These integrations were achieved through specialized assembly processes introduced during retooling, allowing Sterling Heights to produce high-volume, feature-rich 1500 variants efficiently. By April 2025, the plant marked a significant with the assembly of its two millionth Ram 1500, demonstrating substantial efficiency gains and solidifying its position as a key hub for light-duty truck output. This achievement underscored the success of the 2016-2018 retooling in adapting to evolving automotive demands.

Vehicle Production

Current Models

The Sterling Heights Assembly Plant (SHAP) primarily assembles the full-size pickup truck, which has been in production there since 2018. This fifth-generation model features a distinctive coil-spring rear , setting it apart from competitors that typically use leaf springs, which contributes to its renowned ride comfort and handling. Key variants produced include the entry-level Tradesman, the mid-range Big Horn, and the premium Laramie, among others like Rebel and RHO, allowing for a broad spectrum of buyer preferences from work-focused to luxury-oriented configurations. The plant's flexible manufacturing lines enable efficient production of multiple trims and configurations on shared assembly processes, supporting an annual output of approximately 300,000 units based on historical averages since the model's launch. The Ram 1500 has garnered recognition for quality, including a predicted reliability score of 89 out of 100 for the 2025 model year and the MotorTrend 2025 Truck of the Year award, underscoring its strong performance in dependability and innovation. Looking ahead, SHAP is preparing for the introduction of the range-extended Ram 1500 REV (formerly the Ramcharger), a series plug-in hybrid electric vehicle designed to offer extended range capabilities. In September 2025, Stellantis canceled the pure battery-electric version of the Ram 1500 REV. Production ramp-up for the 2026 model is slated to begin in early 2026 following pilot builds, with the plant's recent $235.5 million investment enhancing its ability to integrate electrified powertrains alongside internal combustion options.

Former Models

The Sterling Heights Assembly Plant began automotive production in the mid-1980s with compact cars derived from Chrysler's platform, marking the facility's transition from missile manufacturing to vehicle assembly. In September 1984, production commenced on the GTS and , both front-wheel-drive compacts aimed at the growing small-car market. These were followed in 1985 by the Dodge Shadow and Plymouth Sundance, P-body variants that shared underpinnings with the architecture for cost efficiency and modularity, allowing Chrysler to produce over 1.3 million vehicles by the end of the 1991 model year. The turbo coupe joined the lineup in 1991, extending the plant's focus on sporty compacts through the early 1990s. By the mid-1990s, the plant shifted to midsize sedans on the JA platform, emphasizing family-oriented vehicles with improved ride quality and interior space. Production of the began in June 1994 for the 1995 model year, alongside its badge-engineered siblings, the (1995–2006) and Plymouth Breeze (1996–2000), all assembled at Sterling Heights to meet demand for affordable, versatile four-door sedans. These "Cloud Cars" represented a key evolution in Chrysler's platform-sharing strategy, with the Sterling Heights facility serving as the primary U.S. site for their assembly until the Cirrus ended in 2000. The early 2000s saw the introduction of the second-generation , further diversifying the plant's output on the JR platform for the 2001–2006 models. Sedan production started in fall 2000, complemented by the Sebring from the same period, which continued until 2010; these models shared components with the concurrent for streamlined manufacturing. The third-generation Sebring (2007–2010), built on the platform, launched in August 2006, followed by the updated convertible in 2008, with the plant hosting ceremonies to mark the model's evolution amid retooling efforts. Similarly, the (2008–2014) was produced alongside these, sharing the JS architecture to support flexible line operations. In the mid-2010s, the plant assembled the , Chrysler's final sedan offering before the shift to truck production, on the extended JS platform. Production of the 2011 model began in December 2010, including both sedan and variants, with the (a rebadged 200 Convertible) added from March 2012 to November 2013 for European markets. The redesigned 2015 Chrysler 200 started in March 2014, incorporating advanced manufacturing techniques, but ended on December 2, 2016, as the facility prepared for its conversion to truck assembly.

Operations and Innovations

Manufacturing Processes

The manufacturing processes at Sterling Heights Assembly Plant (SHAP) follow a structured workflow optimized for heavy-duty truck production, beginning with the body-in-white (BIW) stage where stamped metal panels are joined using robotic to form the vehicle's structural frame. This phase involves thousands of precision welds per vehicle to ensure rigidity and safety, primarily executed by automated systems to maintain consistency and speed. Following BIW construction, the body undergoes a multi-stage painting process utilizing eco-friendly waterborne paint systems, which reduce emissions while applying durable basecoats and clearcoats via robotic applicators for uniform coverage and corrosion resistance. The plant achieves a high level of automation, with extensive robotic integration in stamping and welding operations to handle repetitive, high-precision tasks such as panel alignment and seam sealing, while human operators focus on quality inspection, customization options like interior configurations, and final adjustments. In the general assembly phase, the painted body is married to the chassis through a series of automated and manual steps, including the installation of powertrain components, suspension systems, and trim elements, culminating in the addition of wheels, doors, and electronics. This integration allows for efficient production of up to 1,400 vehicles daily on a 24/7 schedule. Quality control is embedded throughout the line with inline testing for dimensional fit, , and structural durability, supplemented by AI-driven defect detection systems introduced in 2022 and expanded in 2024 that use cameras and algorithms to identify anomalies like weld imperfections or paint inconsistencies in real-time, reducing rework and enhancing output reliability. integration supports these processes through just-in-time delivery from the adjacent Sterling Stamping Plant, which provides critical components such as hoods, doors, and roof panels directly to the assembly line, minimizing and enabling seamless . In November 2025, SHAP hosted Stellantis' Factory Booster Day, showcasing innovations including a VR forklift training simulator for safer operations and AI-powered predictive maintenance systems to minimize downtime.

Investments and Upgrades

In 2010, Chrysler Group invested nearly $850 million in the Sterling Heights Assembly Plant to modernize facilities and avert closure, including the construction of a state-of-the-art 425,000-square-foot paint shop and upgrades to machinery and handling systems. This investment supported the plant's transition to producing new vehicle models and added a second shift, enhancing operational capacity. By 2016, committed $1.48 billion to retool the facility for next-generation 1500 production, incorporating advanced assembly technologies and supporting the shift from . This funding enabled the installation of new body shop equipment and improved production lines, positioning the plant as a key for light-duty output. In September 2024, announced a $235.5 million investment specifically for the Sterling Heights Assembly Plant as part of a broader $406 million commitment across three facilities, focused on preparing for including the battery-electric Ram 1500 REV (planned for 2027 model year) and Ramcharger (range-extended , starting early 2026). This upgrade includes new conveyor systems, automation for battery integration, and processes tailored to BEV assembly, aligning with ' multi-energy strategy and contributing to larger U.S. investments exceeding $13 billion announced in October 2025. Technological enhancements at the plant incorporate Industry 4.0 elements, such as IoT-enabled sensors for monitoring and on critical assets like pumps and fans, which help identify issues early to minimize . improvements include optimizations to the HVAC system via plant upgrades, achieving a 50% reduction in chilled water energy consumption through advanced controls and equipment retrofits. The facility has earned ISO 14001:2015 certification for its , demonstrating commitment to sustainable practices in and assembly operations.

Future Outlook

Planned Developments

The Sterling Heights Assembly Plant is undergoing retooling to become Stellantis's first U.S. facility capable of producing electrified full-size pickup trucks, with a focus on multi-energy architectures that include , hybrid, and internal combustion options. In September 2025, Stellantis discontinued development of the all- Ram 1500 REV due to slowing for pure EVs in , redirecting efforts toward the range-extended (REEV) variant, renamed the Ram 1500 REV, which pairs a 92 kWh with an onboard generator for enhanced range up to 690 miles. This shift aligns with the plant's $235.5 million investment announced in September 2024, which includes new for integration and electrified assembly to support upcoming launches. The Ram 1500 (REEV) will mark the plant's entry into electrified production, built on the STLA Frame unveiled in November 2024, a flexible architecture designed for full-size trucks and SUVs with capacities for up to 500 miles of electric-only range in BEV configurations and seamless integration of systems. Although the pure version was canceled, the enables future expansions to additional Ram variants, such as enhanced towing-focused models or larger heavy-duty options, while maintaining compatibility with the plant's existing Ram 1500 assembly lines. Retooling efforts incorporate dedicated areas for handling and testing, ensuring efficient for electrified components without halting current production. Production timelines for the 1500 REV (REEV) have faced amid quality improvements and adjustments, with orders now projected for the first half of 2026 following earlier 2025 targets. The 2025-2027 retooling phase at Sterling Heights includes phased upgrades that may cause temporary reductions in output volume, as seen in similar transitions at other facilities, to support the company's ongoing strategy under the revised Dare Forward 2030 plan. This goal supports broader , with SHAP contributing through its high-volume capabilities across types once fully optimized. Stellantis engineering teams collaborate closely with the plant for on-site validation and testing of advanced features, including powertrain integration and efficiency enhancements for the STLA Frame lineup, building on recent milestones like the assembly of the two-millionth Ram 1500 in 2025. These efforts emphasize rigorous , with and pilot assembly processes at the facility enabling real-world simulations for upcoming electrified models.

Economic and Community Impact

The Sterling Heights Assembly Plant serves as a major economic driver for the region, generating approximately $1.6 billion in annual economic activity that benefits Sterling Heights and the broader metropolitan area through direct operations, supplier networks, and related industries. This impact stems from the plant's role in producing high-volume vehicles like the Ram 1500, which sustains a complex and contributes to Michigan's sector. The facility employs around 3,700 workers directly, providing stable wages and benefits that circulate within the local economy, while indirectly supporting additional employment in , parts , and services across the . Community engagement efforts at the plant emphasize and workforce development, with UAW Local 1700 leading initiatives such as scholarships and training programs to prepare residents for manufacturing careers. , through its foundation, partners with schools to advance education, including support for over 80 FIRST teams that foster skills in and among students. These programs aim to build a pipeline of skilled labor, enhancing long-term and aligning with regional economic goals. On the environmental front, the plant has implemented initiatives to minimize its footprint, achieving the lowest volatile organic compound () emissions among Stellantis assembly facilities at 5.25 grams per square meter of painted surface in 2022, well below the company average. As part of broader Stellantis efforts, the facility contributes to the company's zero-waste-to-landfill ambitions, with 65% of global plants, including North American sites, reaching this status by diverting waste through and recovery processes. The plant has navigated economic challenges that affected the community, notably during the 2009 automotive crisis when widespread layoffs strained local resources, as the industry once accounted for nearly 20% of Sterling Heights' tax base. These impacts were partially mitigated through federal Trade Adjustment Assistance programs, which certified nearly 1,000 affected autoworkers for retraining, re-employment services, and skill development to facilitate transitions within the sector. More recently, the April 2025 milestone of producing the 2 millionth —a Flame Red 2025 Ram 1500 RHO—drew community participation and reinforced local pride in the plant's enduring contributions.

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