The H2: moving beyond limits organizational & otherwise - Engineer - General Motors' Hummer H2 development

Automotive Design & Production, July, 2002 by Gary S. Vasilash

This is one serious piece of machinery. It can ford water 20-in. deep. It can go over obstacles 16-in. high. The H2 features the highest approach and departure angles of any GM full-sized trucks (40.4[degrees] approach and 39.6[degrees] departures for the standard coil suspension version; there is an optional air spring suspension), thanks to short overhangs: 32.6-in, front and 34.6-in, rear. The tires, BF Goodrich LT315/70R-17s on 17.0 x 8.5-in, forged aluminum wheels (the largest size in any GM light truck), are pushed way out to the corners of this vehicle.

Under the SMC hood there is a 364-in. (3) Vortec 6000 V8 (316 hp @ 5,200 rpm; 360 lb.-ft. torque @ 4,000 rpm) that's mated to a 4L65-E four-speed, automatic overdrive transmission. An electronic throttle control system employing a Hitachi throttle body is deployed. A Borg-Warner two-speed electronically controlled full-time four-wheel drive system is used. There are five modes available through the transfer case via pushbutton: 4 Hi Open (normal driving); 4 Hi locked (slippery conditions); 4 Lo Locked (off-pavement traversing); 4 Lo Locked and Locking Differential (optimal for slow-speed climbing and other demanding off-road encounters); Neutral. There is a Bosch four-channel antilock braking/traction control system, as well.

Of course, anyone who is buying an H2 (pricing starts at an MSRP of $48,800) is undoubtedly going to spend time on the road. While the H1 is often cited as being the proverbial go-anywhere vehicle, it is said, in the same breath, to be one that is comparatively lacking in creature comforts. Which is certainly not the case with the H2, which includes eight-way power seats, dual-zone climate control, Bose sound system, and serious sound insulation. Not only are there standard options packages, but GM Service and Parts Organization (SPO) worked with the HUMMER team to create various H2-specific aftermarket products (e.g., wraparound grille guard, tubular assist steps, roof-mounted spot lamps) that fall within the purview of the GM new vehicle warranty.

FAST FACTORY. Jim Armour, CEO of AM General, pointed out that companies have struggled to build vehicles in the 25,000 to 50,000 annual volume range. "With GM," he stated, "we're going to prove that it can be done in a timely manner, at an affordable cost, and with world-class quality." So they built a new 630,000-[ft.sup.2] plant. in 16 months (from August 2000 to December 2001). While the greenfield plant was going up (next to the plant where the military vehicles and His are built), area managers and other personnel spent a year at the GM Manufacturing Integration center, learning about the Global Manufacturing System. Although people were hired from the outside for the new facility, those who were working at the original plant had the opportunity to participate in a day-long session during which they learned about GMS and had a practical exercise that simulated the process of manufacturing a product under a lean approach. They were given the opportunity to switch over to the new facility if they were inte rested in committing to the lean approach. About 10% of the people from the original plant did so, Armour said.