The Lordstown Production Schedule for the 1978 model year

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The Lordstown Production Schedule for the 1978 model year

Postby marco_1978_spyder » Wed Feb 27, 2013 1:17 pm

In this thread I'm going to do something I've been thinking of doing for quite a while now. I haven't found a suitable way to post this info on a blog or online calendar of some sort's.. so I'm going to start it on here and see how it goes.

I could even wait on this thread until August of this year, and do a "35 years ago today", day-by-day entry..

Each Post by me will be of a production cycle day from the *Model Year* 1978 at Lordstown Ohio. 1978 is the year that the Monza, Sunbird, Skyhawk and Starfire models of the H body line, the "Hspecials" were moved to the Lordstown Ohio plant. The plant had been making the H body Vega and Astre for quite a few years, so the new assembly was not a major change over for the plant, however, new assemblies and assembly procedures would have to be learned by some.

The last Vega ever (well the last body badge'd as a Vega since we all know a '78 monza 'S' and '78 wagon were really re-badged Vega's).
vega1.jpg
vega1.jpg (73.52 KiB) Viewed 1824 times

This last Vega pictured here (Highest Vin # ever found..above known production totals) Rolled down the assembly line in early June, 1977 along with 1977 Monza Town Coupes and Sunbird Coupes that had been added in **February to get the line workers familiar with the slight changes in assembly procedures..


**Earlier in the year, the plant was shut down for 5 weeks to adjust the assembly line for the new (to this plant) line up of 2nd generation H bodies, for all 4 divisions. The plant Started making 77 monza town coupes, and Sunbird coupes at this time. Along with the final Vega's.

The V8 Engine installation was new this year for this plant. It had already been accomplished in the St.Therese Quebec, Canada Plant for 3 years.
The Engine line had to be adjusted to install engines from the top. The new V6 and V8's couldn't be installed from below like the Vega 140 4cyl.

The paint department got an upgrade to be able to paint and prep the new urethane parts on the Monza and Sunbird.
This was done during the first 5 week shutdown from Jan, 1st 1977 to Monday morning Feb 14th of 1977.

The line ran one shift at 85 per hour, only 14 an hour were Monza's and or Sunbird's.

The line for 1977's was totally stopped on July 22nd, 1977.

This later shut down allowed for the final changes to be made to accommodate the Coupe and Hatchback versions in 4 different makes. Chevy, Pontiac Buick and Olds. (See this thread for similar info viewtopic.php?f=1&t=40689 and this one for pics..viewtopic.php?f=1&t=40690

It would be restarted again, running the full 1978 line-up on August 22nd, 1978 as shown in the post below.
At first, The plant ran one eight hour shift.
A second eight hour shift was added on October 4th.
With the line running at 70 cars per hour that equaled 1,120 cars per 16 hour production day.

The H body Model year, like most other cars.. started in August of the previous year. So to begin at the 1978 Model Year means to start at the date of Monday, Aug 22nd 1977... The plant ran right on to August 18th of 1978. 242 days of assemblies. 267,531 assembled vehicles. That actual total equals the above totals. That's @ 1096 cars per day.. 69 Car's an hour.. Over one per minute. Leaving the plant under it's own power and into the shipping yard.
As sales remained strong some overtime saturdays were involved. Trim tag data has revealed some of these.
It had been the first time the plant had assembled in overtime hours since 1973!

So 242 post's in all. Detailing and documenting any cars with information submitted. The thread will be a locked thread to keep the info concise. If you have a car to add, PM me the details and we'll go from there.. Thanks for reading hope you enjoy..
There's a companion discussion thread available here.. viewtopic.php?f=16&t=39170

Day's with real data will have Trim tag! and Build sheet! in bold letters.

Hope you enjoy this!
Attachments
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1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
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08D 01-0001

Postby marco_1978_spyder » Wed Feb 27, 2013 1:24 pm

Monday, August, 22 1977: The Very First day of Production for the 1978, Ohio Built, Skyhawk, and Starfire. and the Monza / Sunbird Hatchbacks..All moved here from the St. Therese plant in Quebec, Canada.

Trim tag Stamps:
Month / Week code: 08D
Production Day Count "XX-XXXX": 01 For today(2-8 hour shifts)
The Last Known Vega listed above.. was in line at 5626 so if the stamping machine was re-started at the very next number the first 2nd Gen built at Lordstown would have been stamped 01-5627. There may have been a few pilot models run that may have been stamped. Or possible, but less likely since it wouldn't have been necessary,the number was reset to 0001. It's an important plant tracking number ...all cars followed this sequential number in line for final assembly. The right parts arrived at the right time based on this sequence.

Body Unit Numbers: @ 000001 <irrespective of make or model.
VIN: Will correspond to Make. Chevy's had 100001 up to 299,999 So they could clock more than 100,000 cars. Olds. started at 300,001. Buick at 400,001. Pontiacs were 500,001.

Buildsheet dates:
Upper left hand corner box #10 "Sched No. Date" includes;
Production Day count see above.
date stamp of 08-22

Large font 4 digit stamping above this number is an unknown code. One theory is that this is the car's 'keycode'. The code used to produce the set of keys and locks for it. This number was written in Wax crayon in the licence plate area. So it may have been a final tracking number for the shipping yard.
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
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08D 02-XXXX.

Postby marco_1978_spyder » Wed Feb 27, 2013 1:59 pm

Tuesday Aug 23,1977.. Line picking up speed, but still moving at a reduced paced to get the team's all set on the new assemblies.

Trim tags. 08D 02-XXXX

Buildsheets 08-23
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
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08D 03-XXXX

Postby marco_1978_spyder » Wed Feb 27, 2013 2:44 pm

Wed, Aug 24th 1977

Tags: 08D 03-XXXX
Buildsheet: 08-24
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
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08D 04-XXXX

Postby marco_1978_spyder » Fri Mar 01, 2013 7:51 pm

Thurs, Aug 25th, 1977

Tags: 08D 04-XXXX
Buildsheet: 08-25
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
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08D 05-XXXX

Postby marco_1978_spyder » Fri Mar 01, 2013 7:53 pm

Friday, Aug 26th, 1977

Tags: 08D 05-XXXX
Buildsheet: 08-26
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
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New week begins: 08E 06-XXXX

Postby marco_1978_spyder » Fri Mar 01, 2013 7:56 pm

Monday, Aug 29th, 1977

Trim Tag!: The very first documented Ohio Built monza known to date.
Month: 08E
Day: 06-2057

1st Example Car.. #24 Aquamarine Blue / Black Cloth, Monza Spyder V8/A/C.
VIN: 1HR07U8U100911 -This car was # 911. (First Spyder? - one of them!) Not many monza's built for a whole week to have gone by.The production line was crawling along slowly due to a shortage of parts, -(see tomorrow's post) UPDATE 11/5/13.. It's now known that the line was only working one 8 hour shift per day. (Until October 4th when a second 8 hour shift was added)
Trim Tag info..
O8E 06-2057 Car was final assembled in line at #2057.
The Body Number is 000834 (Hey wait...body number is lower than the vin??? Yep... this shows that this phenomenon was happening right off the bat.
This Body may have been pulled for inspection and re entered into the line, or may have had to be reworked. Or simple sat in a "Body Bank" for an extended period before being picked for assembly as Monza #911).
"02blk" = Z02 equipped (Spyder Decals) in Black. This code informed the body shop to drill the proper holes for the Z02 spoilers, and also told the paint shop to add the special painted on black out parts. The proper color decal set was listed on the Buildsheet in the "Hydropierce" box (#55) on the buildsheet. Only the trim tag info is available for this Car.

Can anyone find / supply an earlier built '78 model?
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
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08E 07-XXXX

Postby marco_1978_spyder » Fri Mar 01, 2013 8:19 pm

Tues, Aug 30th, 1977

The line was Halted today. There was a shortage of parts (alternator's) due to a strike at a Delco Remy plant in Anderson Ind.
The line had been moving Slowly for a few days. The previous Thursday it was reported that the line was crawling at only 43 unit's per hour.

08E

07-XXXX

8-30
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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08E 08-XXXX

Postby marco_1978_spyder » Sun Mar 03, 2013 11:56 am

Wed, Aug 31st, 1977

08E 08-XXXX

08-31

No examples for this day...have one to share? PM me.
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
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08E or 09A 09-XXXX

Postby marco_1978_spyder » Sun Mar 03, 2013 3:44 pm

Thurs, Sept 1st, 1978 ... Line likely up to speed. Workers assembling part's to your car in under 40 second's.

Trim tags may be stamped 08E or 09A. Either way it was the 9th day of production.

No records for this day build sheets should show this day as 9-01. Any matching buildsheets out there?
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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08E or 09A 10-XXXX

Postby marco_1978_spyder » Sun Mar 03, 2013 3:47 pm

Friday, September 2nd, 1978

09A 10-XXXX

No records for this day. build sheets should show this day as 9-02. Any matching build sheets out there?
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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09A 11-XXXX

Postby marco_1978_spyder » Sun Mar 03, 2013 4:04 pm

****Monday, September 5th, 1977**** This was Labor day.... Trim tag and build-sheet dates suggest some time off between the entries I have.
The most logical conclusion was that there was an extra day off around Labor day along with Labor day itself.
I'm using Monday and Tuesday, September 5th and 6th as the long weekend. But it may have also been the previous Friday.
Build-sheets will confirm this if any are ever submitted.

Production Day 11,

Wednesday, September 7th, 1977

Trim tag's should read 09A 11-XXXX

This day *should* read 09-07 <Submitted examples will help verify actual dates.

As a general note/reminder: Build sheets would have these trim tag codes and an actual calendar date printed just below. As found in the box in the upper left hand corner.
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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09A Production Day 12

Postby marco_1978_spyder » Sun Mar 03, 2013 4:43 pm

Thursday, September 8th, 1977

09A 12-XXXX

09-08

No current examples.

I made a change to the header format. It now says "Production day XX"
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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Posts: 5275
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Location: Western, New YorK / Rochester

09A Production Day 13

Postby marco_1978_spyder » Sun Mar 03, 2013 4:51 pm

Friday, September 9th, 1977

09A 13-XXXX

09-09

No examples submitted..
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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Posts: 5275
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Location: Western, New YorK / Rochester

09B Production Day 14

Postby marco_1978_spyder » Sun Mar 03, 2013 7:37 pm

Monday, September 12th, 1977

09B 14-XXXX

09-12

On a day like today some 1,100 cars would be built. Early records show the line starting up slowly, but to build 267,531 Vehicles in 242 days mean's about 1,100 cars daily once the line was up and running in high capacity mode.

Some basic math suggests that's:
570 Monza's
360 Sunbird's
100 Skyhawk's and
70 Starfire's
On Average, Are built Per day.

Because of the slow beginning week the totals below have been reduced a little

As of this production day we would have about:

7000 Monza's
4200 Sunbird's
1300 Skyhawk's
910 Starfire's

So By Now, the first Ohio Built H specials, would be arriving at dealership's nationwide. At least 10,000 have been built.
Thats more than one each, for the 5 thousand or so Dealerships nationwide.
1978 Monza Spyder V8 4speed, posi
1978 Sunbird Formula V6, 5 Speed, Hatchback
1980 Sunbird Hatchback 4cyl, 4spd.
2006 Chevrolet Aveo 5 speed Hatchback
Yes, you can refer to me as Mark
Please visit my blog... http://chevymonza.blogspot.com/ Follow if you like!
Featuring special guests; Carl Beraytor and Ray D'atore

My Red spyder now has a youtube channel please Like and Subscribe!!!
https://www.youtube.com/channel/UCOzzSR ... ISuing7KLA
User avatar
marco_1978_spyder
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Posts: 5275
Joined: Sun Jun 25, 2006 5:20 pm
Location: Western, New YorK / Rochester

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