Saturday, July 15, 2023
I returned home late last night from a 2-day trip to Waterloo, Iowa. There, my son Ben and I took part in a “Gold Key” experience at the John Deere Waterloo tractor factory. We were there to see our new 9R 540 tractor get built. Wow!
It’s about 7 hours drive from here to Waterloo. I met Ben at Covington, Indiana at noon on Thursday. Of course, we had a great lunch at the Beef House there.
Ben and I never want to miss an opportunity for a meal at the Beef House!
As we drove towards Iowa, we stopped off for a brief visit at the John Deere Pavilion in Moline, Illinois. The exhibits there were impressive, and the adjoining John Deere Store was a good place to pick up souvenirs for this trip.
Just before our arrival in Waterloo, we drove through a strong rainstorm. I had to slow the pickup to about 35mph on I-380 for about 1o minutes as we were pounded with heavy rain, making visibility pretty low. But it passed, and the sky brightened as we entered Waterloo. We got settled into our hotel, and then found a place for supper. We went to a place called LJ’s, and it was really good!
Yes, LJ’s was pretty good!
Friday morning, it took us about 15 minutes to drive out to the factory site. Arriving there, we parked in the special “Gold Key Customer” spot. Upon entering the building on time at 730 am, we were welcomed by our guide for the day, Gary Vick. Gary was retired from 40 years of working at this factory. He was assisted through the day by Jayson, who provided us some welcome transportation around the 45-acre building.
Finding our “Gold Key” parking spot
Just inside the front door is this very welcoming lobby.
With Gary Vick(L), our host for the day. That’s Ben on the right
This factory is an ‘assembly’ location, for many components are built in other facilities, then transported to this plant to be installed in the tractors. Engines are built in another facility near Waterloo, as are the transmissions in the “Drive Train Component” factory. All the castings are made in a foundry at Waterloo. The foundry is electric powered, not coal or gas. It uses in one day the amount of electricity that would be used by the twin cities of Waterloo and Cedar Falls for a month!
After an orientation film, we went directly to the 9R assembly area. We saw the tractor main frames and center hinge and axles come together. Then, those basic assemblies are sent off to receive a coat of that unique John Deere green paint.
First stop was to add a pin on the map for where our Gold Key tractor was going
We found pins for Gold Key Customers from all over the world
After paint, these basic frames are placed on a robotic cart that moves them along the assembly area. It was very interesting as we were directly on the assembly line, speaking with the folks who were doing the build. At each of the 30-or-so stations on the line, we found these people to be eager to explain what they were doing, and how the computer system guides and verifies their work. Each tractor is rather unique, no two are exactly alike as they travel down the line. Therefore, the work of the assembly folks is typically different for each tractor that comes to their station. When each station has completed their tasks, then all the tractors on the line move ahead to the next station. The tractors spend 30-40 minutes at each station. We saw the transmission go in, then wiring harnesses and hydraulic lines. The hydraulic reservoir was massive. Then the engine goes in and is connected. The radiator system is next, the the cab drops down from above to be fully connected. The fuel tank and DEF systems go on, plus the LH side steps and batteries.
Here is the main frame of our 9R tractor, just back from the paint process, and ready to move down the assembly line. It is carried along by a specially-designed robot.
Another view of the main frame and axles of the 9R 540.
I got to closely observe the installation of the main drive line between the engine and the transmission. Paul, the person at that particular station, got me to step up a set of portable stairs, and watch as he bolted in place the U-joints on each end of the driveshaft. Of course, the wrench he used was suspended from a robot-like, many-jointed arm, and, like every other device at the station, was controlled and verified by the station’s computer system. After the driveshaft was secured in place, Paul also bolted down a heavy cast iron shield around it, one that would absorb any impact if for any reason the driveshaft failed.
Nearing the end of the assembly line, the tractors go into a special testing room where the fluids are added, the engine is started, and those systems are examined for any leak or problem. When the testing is complete and the tractors move out of that room, the beautiful and sleek green hood is mounted. It was interesting to see the technicians skillfully apply the yellow decal stripe to each side of the hood, guided only by their keen eye, steady hands, and years of experience.
Although this is not our tractor, this is how this expert applies the decal that proudly bears the John Deere name.
Our tractor is also a specially-equipped “Signature Edition”, which means it has just about every deluxe optional feature that John Deere offers on a 9R tractor.
Nearing the end of the main 9R assembly line, the wheels or tracks get installed, which is a fascinating thing to watch, too! Then, one final inspection station. After that, the tractors are driven out the ‘back door’. From there, a transportation company takes custody of the tractors, and they really don’t belong to Deere any more. The transportation company is responsible for them until they arrive at the dealer. If the tractors are headed for any North American dealer, they are typically transported by truck. If they are headed overseas, they go by train to Charleston, SC or Seattle, WA to be loaded on one of those huge cargo ships.
In the 8R assembly portion of the factory, we got to participate in the build! We were asked to tighten down the bolts on a cab mount, Ben on the right side, and me on the left. The computer-controlled wrench was suspended on a robot-like arm, easy to maneuver, and a green light flashed when the bolt was snugged to the exact torque required. Fascinating stuff.
Ben operates the special tool to tighten down the cab mount. Computer controlled– and it electronically verified the finished task.
I even got to do the same task as Ben, just on the left side of this 8R tractor.
After a delicious lunch in the cafeteria, we toured the cab assembly line. There, we saw a front windshield have the adhesive applied by a robot, and then placed precisely in position by a tech assisted by a robotic arm. Amazing. Every stop on the tour was personal, pretty much ‘hands on’, warmly received by the factory techs, and complete with information on the “hows” and “whats” and “whys” of what they were doing. We walked a lot and we learned a lot.
Here’s a view of the 9R assembly line. The tractor you see is a 9RX. See how clean it is in this place?
As the tour came to an end, we were escorted back to the welcome area at the front. There we were given some gifts, a thumb drive with the pictures taken that day, and a beautiful certificate to commemorate the day. Lastly, we received a special golden key for the tractor. We left at about 245pm for the drive back to Indiana.
We came away even more impressed with John Deere. The factory was remarkably clean. It was comfortable too–even though it was 93ºF outside, it was pleasant inside. Besides winsome hospitality, you see just how exacting is the process from design to driving away the final tractor. I asked Gary how many different parts were in a typical 9R tractor, and that was a question he could not answer. I would guess tens of thousands. The computer systems that guide the build process was impressive. It seemed to me that this was like a great system of streams flowing along precisely as tributaries to a river. Each part or assembly flowed to the exact spot needed at exactly the right time, for each unique tractor. How that all comes together with such precision is amazing.
All over the plant were video screens to announce our Gold Key visit. There were two other Gold Key visitors that day.
To say we had a “good time” is too small a comment. I will get a ‘thank you’ off to Gary and Jayson next week to express our appreciation for a magnificent Gold Key Experience.
Here it is…
Eager to use it in the new tractor!
