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How two Michigan stamping plants power Stellantis turnaround plan

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How two Michigan stamping plants power Stellantis turnaround plan


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Warren — Hulking metal presses line one wall of Stellantis NV’s cavernous stamping plant here, punching out the raw shapes of Jeep doors, Dodge hoods and Ram tailgates in rapid succession.

Nearby, swinging yellow robots continue the tightly choreographed work, gluing and pressing and welding smaller components to the sheet metal that eventually will start to resemble the shape of a truck or SUV.

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Seven miles north, in Sterling Heights, Stellantis operates an even larger stamping plant — the biggest in the world, at 2.7 million square feet — that does much of the same work, churning out various shapes of steel and aluminum 24 hours a day.

Together, these lesser-known links in the manufacturing supply chain support all of Stellantis’ big North American assembly plants — from next-door Warren Truck Assembly Plant, where the Jeep Grand Wagoneer SUV is built, to facilities in Windsor and Mexico that make minivans and pickups.

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Inside Stellantis’ Huge Detroit Stamping Plants

The Detroit News recently got a rare look inside the automaker’s Sterling and Warren stamping plants, which are key to the company’s turnaround plan.

The Metro Detroit stamping plants, the automaker’s only two such facilities in the United States, have at times struggled in recent years, facing major job cuts and worker morale issues amid slowing sales and shifting production plans. But under Stellantis CEO Antonio Filosa, the facilities are expected to cram in more workload — and add staff — as Stellantis begins a new five-year strategic turnaround plan, which includes a heavy focus on its most profitable North American market.

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The carmaker’s goal: grow sales by more than a third to 1.9 million annually by 2030 as it launches 23 vehicles, including 11 all-new models. The company also is directing billions of dollars of investment into its U.S. manufacturing footprint due to President Donald Trump’s tariffs.

“Stamping has never really been viewed as the sexy side of automotive manufacturing, we’re relatively invisible,” said Ed Daniels Jr., vice president of North America injection and stamping operations. “Because when you look at the commercials and advertisements, it’s always a beautiful Ram rolling off the assembly line or climbing the side of a mountain.

“But we’re the inception of that vehicle,” he said. “This is where raw materials are turned into commodities and parts.”

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The Detroit News recently got a rare look inside the two plants that combined employ about 3,000 people. The automaker wanted to show off a newly-installed blanking press at Warren Stamping and other machinery like a high-speed transfer press and a robot that spots flaws in the metal.

Hiring expected

The blanking press unspools long coils of metal and chops them up into pieces that can then be shaped into roofs, fenders and floor pans. Stellantis shipped the massive machine to Warren from its idled Belvidere Assembly Plant in Illinois last year.

After upgrades to the machine, executives said it’s able to produce as many as 120,000 metal blanks per week. It will save Stellantis money since the plant will no longer need to pay a supplier to break down the coils before the metal arrives there.

The blanker addition is a big deal for the plant and signals that the company wants to bring more work in-house and invest in the facility over the coming years, said Romaine McKinney III, president of United Auto Workers Local 869, which represents workers at the factory.

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The plant has already brought back all of its laid-off UAW workers, and McKinney said he anticipates more hiring to get underway if sales grow and new Stellantis vehicles come to market.

In another corner of the Warren facility, one of the fastest press lines in the world — known internally as the Hellcat — pushes as many as 15 pieces of metal through per minute. Dies that weigh up to 50 tons apiece squish the material into the shapes of doors and hoods before robotic arms snatch them out and place them on conveyor belts. Midway through a shift, workers can reconfigure the machine to make a different component, a process that takes just five minutes.

Robots check for quality

Curtis Booth, who manages Warren Stamping, said manual processes inside the plant have become increasingly automated, and safer, over the last couple decades, even as the automaker’s two stamping factories still utilize some presses that were installed in the 1960s.

The latest high-tech addition is the Automated Body Inspection System, or ABIS. It’s a camera system mounted on a robot that automatically checks the quality of components and flags anything in need of repair.

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Auto plants of all kinds are increasingly turning to these types of camera systems, infused with artificial intelligence, to catch flaws in sheet metal and other components before they are shipped. Booth said worker visual inspections are still used. But in some cases the human eye has too much subjectivity, and the ABIS removes the guesswork.

Greg Bauer, who manages Sterling Stamping, said his plant has added staff over the past year, and expects to continue hiring as more work is assigned to the facility. There is no space at the plant to add more presses, but officials have figured out how to increase efficiency — quickly toggling back and forth between making doors for a Chrysler Pacifica and Dodge Charger on on a single machine, for example.

“We want to bring high-volume parts into the plant, and we want to maximize the capacity of the equipment,” Daniels said.

lramseth@detroitnews.com

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Michigan Public Service Commission hosts workshop on utility affordability

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Michigan Public Service Commission hosts workshop on utility affordability


The Michigan Public Service Commission (MPSC), which is in charge of regulating utilities, hosted a workshop in Grand Rapids Tuesday seeking to inform the public on what goes into their bills but also get feedback.

For two and a half hours, commissioners and MPSC staff conversed with ratepayers on a variety of topics in regard to electricity and gas utilities.

“There’s an old dictum that the commission speaks through its orders, but in addition to speaking, we need to listen,” Commission Chair Dan Scripps said. “This is a great opportunity to to listen to the people who ultimately pay the bills at the end of the month.”

The commission noted Michigan utility costs have actually risen 5% below inflation, but acknowledged that’s still high.

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“You’ve got one in four Americans today that are having to make those impossible choices between paying their electric bill or their gas bill and feeding their family or paying for medicine that they need,” Scripps said.

Constant rate hikes were a chief concern among attendees in conversations with staff, but also the impact of data centers on power bills.

Advocates like Wende Randall, director of the Kent County Essential Needs Task Force, were in attendance. She said their hotline receives a lot of calls from people unable to afford their utilities.

“The presentations went into a level of detail that we haven’t heard in a community forum like this before,” Randall said. “I think that was really helpful. But also having the opportunity to interact directly with staff and with commissioners is a really important way for us to be able to support our community members.”

The commission welcomed the feedback while putting forth potential legislative solutions.

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Monday, they sent a letter to Gov. Gretchen Whitmer providing recommendations.

“We literally go through these cases and we also know the limits of our authority under current law,” Scripps said. “So it’s a chance to say, ‘here are some things that maybe aren’t part of the conversation yet.’”

Among the 19 policies the commission wants to see, a ban on yearly rate cases, a rule to tie earnings to cost efficiency, requirements that utilities augment existing infrastructure before investing in costly upgrades.

They also recommend requirements that data centers pay the full cost imposed on the grid and an expansion of efficiency and assistance programs.

“There’s a system that that needs a lot of investment, we’re not where we want to be on reliability, but how do you balance that with the costs that customers pay and do it in the most cost effective way possible,” Scripps posited.

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The MPSC will take what they heard from attendees in Grand Rapids and a second session in Detroit and factor that into rate cases and regulations.

Scripps said public input has already done a lot to transform what the agency does.

“We’re there to serve the public, and I will say, when you listen to people, you ultimately walk away with, with more than you started with,” he said.



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Michigan father charged in Thanksgiving Day crash that killed 5-year-old daughter heads to trial

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Michigan father charged in Thanksgiving Day crash that killed 5-year-old daughter heads to trial



A Michigan father charged in a fatal Thanksgiving Day head-on crash that resulted in the death of his 5-year-old daughter will stand trial. 

During a preliminary examination on Aug. 7, 31-year-old Austin Thorpe of Lapeer was bound over on eight felony charges and four misdemeanor offenses in connection with a deadly November 2025 crash. 

Thorpe was bound over on one count of involuntary manslaughter, three counts of operating while intoxicated causing serious injury, one count of operating while intoxicated causing death, two counts of third-degree child abuse, three counts of moving violation causing serious impairment, one count of moving violation causing death and felony commission with a motor vehicle. During the preliminary examination, a judge added involuntary manslaughter charges and a second count of operating while intoxicated causing serious injury and a moving violation causing serious impairment. 

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Thorpe is charged as a second-offense habitual offender. 

The crash happened on Nov. 27, 2025, when prosecutors say Thorpe was driving a 2011 Chevrolet Impala southbound on M-53 in Bruce Township when he crossed a center turn lane and crashed head-on with a 2013 Chevrolet Impala in the northbound lane. 

Thorpe, his children and the driver of the other vehicle were taken to a local hospital, where his 5-year-old daughter later died. 

Prosecutors allege that Thorpe did not properly secure his 2-year-old son and 5-year-old daughter in the car. 

“The allegations in this case are deeply disturbing. The defendant is accused of driving while impaired and failing to properly secure two young children before a crash that tragically claimed one child’s life, seriously injured another, and badly hurt an innocent driver. My office will aggressively pursue accountability based on the evidence and seek justice for the victims and their families,” said Macomb County Prosecutor Peter J. Lucido.  

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Thorpe is scheduled to be arraigned in the Macomb County Circuit Court on Aug. 24. 



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Michigan man charged in stabbing at Raft Off event on Lake St. Clair

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Michigan man charged in stabbing at Raft Off event on Lake St. Clair


A 26-year-old Shelby Township man appeared in court on Monday after he allegedly stabbed another man over the weekend at the Raft Off event on Lake St. Clair.

Court records show that Salem Asmar was charged with one count of assault with intent to do great bodily harm less than murder.  According to the St. Clair Sheriff’s Office, Asmar allegedly stabbed a 21-year-old man following a disagreement at Saturday’s event.

Asmar was arraigned and received a $100,000 cash/surety bond. He is due back in court on Aug. 19 for a probable cause conference, according to court records.

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The sheriff’s office says the incident involving Asmar was one of the multiple fights that broke out at the Raft Off. Additionally, authorities say more than 50 people were left stranded after failing to return with the party they arrived with.

“We welcome all to enjoy come enjoy Lake St. Clair, but violence is not something that will be tolerated on the water.  Our Marine Deputies take safety seriously, and those who are behaving irresponsibly or are breaking the law will face consequences,” Sheriff Mat King said in a statement.

The sheriff’s office says a record number of people showed up for the annual summer boat party at Muskamoot Bay. The event, which has no official organizer, is considered one of the largest on-water gatherings on the lake.



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