LANSING -For the first time in 15 years, General Motors is building a new assembly plant on U.S. soil.

But when they get around to building 'em, they build 'em big.

GM, the building trades, construction manager The Washington Group, and hundreds of subcontractors are in the process of building the new Lansing Grand River Assembly Plant, a $560 million project spread over nearly two million square feet of space. An astounding number of construction workers - about 1,200 - are currently putting their skills to work on the fast-track, two-year project, scheduled for completion on Nov. 12.

"We're on-schedule, and we're really pleased with the trades workers on this project," said GM Project Manager Dale Griffith. "We were very concerned about manpower shortages, but the Lansing Building Trades did an outstanding job of getting good, motivated workers."

The new plant is GM's first to be built in the U.S. since the Saturn Plant in Spring Hill, Tenn. was completed in 1986. The site consists a body shop, a paint shop and a general assembly building, and will build the next generation Cadillac Catera and other luxury vehicles.

GM has had some experience in building new plants over the last 15 years, having erected assembly plants in Poland, Argentina, China, Brazil and Thailand.

"Lansing Grand River gives us the opportunity to merge our best manufacturing processes from around the world," said G. Richard Wagoner, GM president and chief operating officer, during a site dedication ceremony. "The experience gained and the lessons learned from these projects will help make Lansing Grand River a truly world-class facility."

This is the first GM plant in the U.S. to be designed using a 3-D computer model - called "a virtual factory" - allowing the automaker to test how systems will work before any concrete is poured or beams are set.

"In the past, we couldn't validate the integration of equipment, tools, fixtures and machinery until everything was set up on the plant floor during startup," said Donald E. Hackworth, senior vice president of GM and group executive for the GM North America Car Group. "With a virtual factory, we are able to computer-model a safer and more ergonomically friendly environment, saving time in the design and validation process, and reducing costs by identifying and resolving problems upfront."

The virtual factory allowed the automaker to erect the 617,000 square-foot general assembly building in approximately half the space as in the past. And, the new plant will include improved material handling system. Supply trucks will deliver materials directly to where they're needed in the plant, with conveyors moving the materials on the inside of the plant, instead of building a single loading dock and using a forklift to transport materials.

The plant, projected to employ 1,500 people by its third year of operation, will be able to shift rapidly from car to truck production, or produce both at the same time. The Olds Alero and Pontiac Grand Am are also being built at existing production facilities on the site.

"We have a good working relationship with the contractors and GM," said Michigan Building and Construction Trades Council Business Rep. T. Jeff Cole. "And we've had to, considering the fact that this project is going from ground zero to full operation in two years."

ONE OF THE LARGEST employers of construction workers in the state is the new GM Grand River Assembly Plant in Lansing. Some 1,200 Hardhats are constructing the all-white Assembly Plant in the foreground, the paint shop and above that, the body shop.

THREADING A WATER line at the GM Grand River plant's paint shop is Kevin Sponseller of Plumbers and Steamfitters Local 85