CHATHAM, Ont. — With upwards of 1,200 orders taken to date for the ProStar, International’s new flagship aero tractor, workers at the truckmaker’s Chatham, Ont. plant are going full tilt readying the plant for the truck’s roll out in January 2007.

The ProStar, the first truck line the OE has introduced in six years, is a result of five years and $300 million in development, including the continuous collaboration of dealer and customer advisory boards.

The lineup, which the company boasts will “revolutionize the class 8 on-highway market in North America,” includes the standard ProStar, the ProStar Premium, the ProStar Eagle, and the top-of-the-line highway tractor the ProStar Limited. It will replace the 9400 Series and eventually take over for the 9200 series as well. Initial production will be based on 122-in BBC tractors with a high-rise sleeper configuration. The second phase of production will include additional BBCs and sleeper configuration options.

Navistar says the ProStar will revolutionized
its manufacturing processes in Chatham.

It has also revolutionized International’s manufacturing processes, especially at its Chatham plant, which has undergone a major modernization, including a complete reconfiguration of the assembly line. The plant is playing a significant part in the tractor’s dynamic innovations and in the expected daily production of a record number of tractors at the plant.

“We expect a flawless launch because we have developed a truly great product using a great process to ensure we understand and deliver on our customers’ buying motivations,” said Tom Baughman, vice president and general manager, Heavy Truck Group, at International. “As the International ProStar represents a new standard for line-haul tractors, the Chatham plant represents the new standard for manufacturing heavy trucks.”

An estimated $270 million has been invested in technology, state-of-the-art equipment, a research-and-development facility, advanced skills and training at the Chatham facility, which employs about 1,700 workers.

The reconfigured assembly line streamlines the ProStar’s production in several ways, including accommodating the truck’s more modular production process. For example, modules for its battery box/air tank and fuel tank come pre-assembled and pre-painted chassis skirts and bottom-hinged, pre-assembled bumpers are all part of the new process design that improves line throughput and efficiencies.

Other modernizing steps include a new chassis spray paint booth that improves paint coverage while reducing paint usage and also makes environmental improvements.

International officials have set a detailed launch-readiness review process that maximizes the value of each build process and lets them review each functional area. A comprehensive ProStar training program is also underway encompassing all functions and including a custom-made initiative to upgrade the skills of plant employees in a variety of areas. The company has also established a final-product quality audit for each shift. The audit reviews each of the five tractors produced per shift with a set list of items from the customer’s perspective. The Chatham plant aims to establish a workplace model for manufacturing long-haul and other trucks.

“You know how you buy a car and all the dealer does is give it a wash and hand you the keys because he’s confident of the quality straight from the factory? That’s what we’re aiming for with the launch of ProStar,” explained Baughman.

International says it will start with a “trickle build” in December to ease ProStar into production at the plant. Engineers want to jump from building 7,000 units in 2007 to 21,000 in 2008.