KUKA Toledo Production Operations (KTPO) celebrated the completion of its two millionth Jeep Wrangler body-in-white.

The wholly owned subsidiary of KUKA Systems North America LLC has built the body-in-white of all Wranglers sold worldwide — both two-door and four-door models — since beginning operations in 2006. It took seven years for the company to build the first million but only four to make the second million because it expanded output to keep up with demand for the vehicle. Body-in-white is the stage of vehicle manufacturing where a car body's sheet metal components have been welded together but no moving parts have been assembled to the frame.

With a fleet of 259 robots, KTPO produces 828 body-in-whites per day over three daily shifts in its 330,000 ft2 body shop. Assembling the body-in-white involves welding the underbody, windshield and closures together. The plant's robotic fleet and 60,000 other inputs are linked to a back-end digital monitoring system and a master data management system. According to the company, the networking of production processes has evolved into an intelligent lifecycle management platform designed to Industry 4.0 principles.